Polaris Magnum 500, Scrambler 500, Trail Blazer 400, Trail Blazer 250, Sportsman 600 User Manual

...

Download

2003

ATV

Universal

Owner's Manual

for

Vehicle Maintenance and Safety

Read this manual carefully. It contains important safety information.

This is an adult vehicle only.

Operation is prohibited for those under 16 years of age.

WARNING

The engine exhaust from this

product contains chemicals known

to cause cancer, birth defects or

other reproductive harm.

We’ve created a web site just for YOU!

S Technical tips

S New product introductions

S Event schedules

S Parts and Service Manual information

S Exciting details about The Way Out

Check it out...

www .polarisindustries.com/owner

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

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

WELCOME

Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products.

Polaris Recreational and Utility Vehicles

S Snowmobiles S All-terrain vehicles (ATVs) S Personal watercraft S Victory motorcycles S RANGER utility vehicles

Polaris Professional Series Workmobilest

S Utility Task Vehiclest (UTVs) S Personal Task Vehiclest (PTVs) S All-Surface Loaders (ASLs)

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, making it the finest machine we’ve ever produced.

For safe and enjoyable operation of your vehicle, be sure to follow the instructions and recommendations in this owner’s manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer (MSD) Technician.

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

We also take great pride in our Parts Apparel and Accessories (PAA) products, available through our online store at www.purepolaris.com. Have your accessories and clothing delivered right to your door!

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

TABLE OF CONTENTS

WELCOME 3.................................

TABLE OF CONTENTS 5......................

VEHICLE IDENTIFICATION NUMBERS 6........

SAFETY 7...................................

CONTROLS 37...............................

FEATURES 48...............................

OPERATION 56..............................

NOISE EMISSION CONTROL

SYSTEM REGULATION 74..................

MAINTENANCE AND LUBRICATION 75.........

POLARIS RECOMMENDED PRODUCTS 141....

TROUBLESHOOTING 142.....................

WARRANTY 146..............................

INDEX 149...................................

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

VEHICLE IDENTIFICATION NUMBERS

The vehicle frame vehicle identification number (VIN)(1) and engine serial number (2) are important for model identification when registering your vehicle, when obtaining insurance, and when ordering replacement parts. If your vehicle is stolen, these numbers are essential to the recovery and identification of your vehicle.

Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys. If both keys are lost, the ignition switch must be replaced. See your Polaris dealer.

NOTE: Record your vehicle’s ID numbers and key number (3) in the spaces provided.

31XX

Frame VIN:

Vehicle Model Number:

Engine Serial Number (right front side of engine crankcase):

Key Number:

Dealer Imprint:

SAFETY

Operator Safety

WARNING

Failure to follow the warnings 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 and understand your owner’s manual and all warnings before operating a Polaris ATV.

Age Restrictions

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

Know Y our Vehicle

As the operator of the vehicle, you are responsible for your personal safety, the safety of others, and the protection of our environment. Read and understand your owner’s manual, which includes valuable information about all aspects of your vehicle, including safe operating procedures.

Safety T raining

When you purchased your new ATV, your dealer offered a hands-on safety training course that covers all aspects of vehicle safety. 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 from a party other than a Polaris dealer, you can request this free safety training from any authorized Polaris dealer.

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

We 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.

SAFETY

Operator Safety

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

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

WARNING

The safety alert warning indicates a potential hazard that may result in serious injury or death.

CAUTION

The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the machine.

CAUTION

A caution indicates a situation that may result in damage to the machine.

NOTE

A note will alert you to important information or instructions.

SAFETY

Operator Safety

WARNING

Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner’s manual.

S Read this manual and all l abels carefully, and follow the operating

procedures described.

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

course. Beginners should receive training from a certified instructor.

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

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

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

S Always avoid operating an ATV on paved surfaces, including side-

walks, driveways, parking lots, and streets.

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

a dirt or gravel road.

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

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

S Never consume alcohol or drugs before or while operating an ATV. S Never operate at excessive speeds. Travel at speeds appropriate for

the t errain, visibility and operating conditions, and your experience.

S Never attempt wheelies, jumps or other stunts. S Always inspect your ATV before each use to make sure it’s in safe

operating condition. Always follow the inspection and maintenance procedures and schedules outlined in your owner’s manual.

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

rests of the ATV during operation.

S Always travel slowly and use extra caution when operating on unfa-

miliar terrain. Be alert to changing terrain conditions.

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

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

SAFETY

Operator Safety

S Always have the ATV inspected by an authorized Polaris dealer if

it’s been involved in an accident.

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

Practice on smaller hills before attempting larger hills.

S Always follow proper procedures for climbing hills. Check the ter-

rain carefully before ascend a hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. Never go over the t op of a hill at high speed.

S Always follow proper procedures for going downhill and for braking

on hills. Check the terrain carefully before you start down a hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle, which would cause the vehicle to lean sharply to one side. Travel straight down the hill when possible.

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

Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you’ve mastered (on level ground) the turning technique outlined in this manual. Avoid crossing the side of a steep hill when possible.

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

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

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

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

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

ice, travel slowly and use extra caution to reduce the chance of skidding or sliding out of control.

S Avoid operating the ATV through deep or fast-flowing water. If it’s

unavoidable, travel slowly, balance your weight carefully, avoid sudden movements, and maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make sudden throttle changes.

SAFETY

Operator Safety

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

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

S Always check for obstacles or people behind the ATV before operat-

ing in reverse. When it’s safe to proceed in reverse, move slowly and avoid t urning at sharp angles.

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

always maintain proper tire pressure.

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

sories.

S Never exceed the stated load capacity for your ATV. Cargo must be

properly distributed and securely attached. Reduce speed and follow the i nstructions in this manual for carrying cargo or towing. Allow a greater distance for braking.

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

prevent unauthorized use or accidental starting.

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

Equipment Modifications

We are concerned for the safety of our customers and for the general public. Therefore, 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. Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury.

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.

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

SAFETY

Operator Safety

WARNING

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

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

HOW TO AVOID THE Beginning and inexperienced operators should complete the

certified training course offered by Polaris. Operators should regularly practice the skills learned in the course and the operating techniques described in the owner’s manual.

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

HAPPEN

HAZARD

WARNING

POTENTIAL Failure to follow the age recommendations for this ATV . WHAT CAN Severe injury and/or death could occur if a child under the

minimum age recommendation operates an ATV. 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 .

HOW TO AVOID THE No one under the age of 16 should operate a Polaris ATV.

HAZARD

HAPPEN

HAZARD

Operator Safety

WARNING

POTENTIAL HAZARD Carrying a passenger on an ATV. WHAT CAN Carrying a passenger greatly reduces the operator’s ability to

balance and control the ATV, which could cause an accident and injury to the operator and/or passenger.

HOW TO AVOID THE Never carry a passenger. The purpose of the long seat is to

allow the operator to shift position as needed during operation. It is not intended for carrying passengers.

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

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

paths, parking lots, and driveways. WHAT CAN ATV tires are designed for off-road use. Operating on paved

surfaces may seriously affect the handling and control of the ATV and could result in loss of control, accident, and/or injury.

HOW TO AVOID THE Avoid operating the ATV on pavement. If it’s unavoidable,

travel slowly and avoid sudden turns or stops.

HAPPEN

HAZARD

Operator Safety

SAFETY

WARNING

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

including dirt and gravel roads. In many states it’s illegal to operate A TVs on public streets, roads and highways.

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

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

protection and protective clothing. WHAT CAN Operating an ATV without an approved helmet increases the

risk of a severe head injury or death in the event of an accident.

Operating without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident.

HOW TO AVOID THE Always wear an approved helmet that fits properly. Always wear eye protection (goggles or face shield), gloves,

boots, long-sleeved shirt or jacket, and long pants.

HAPPEN

HAZARD

Operator Safety

WARNING

POTENTIAL HAZARD

Operating the ATV after consuming alcohol or drugs.

WHAT CAN

Consumption of alcohol and/or drugs could seriously affect

operator judgment. Reaction time may be slower and operator

balance and perception could be affected.

Consuming alcohol and/or drugs before or while operating an

ATV could result in an accident causing severe injury or death.

HOW TO AVOID THE

Never consume alcohol or drugs before or while operating an

ATV.

HAPPEN

HAZARD

WARNING

SAFETY

POTENTIAL

Operating the ATV at excessive speeds.

WHAT CAN

Excessive speed increases the operator’s chance of losing

control of the ATV , which can result in an accident.

HOW TO AVOID THE

Always operate the ATV at a speed that’s proper for the terrain,

visibility and operating conditions, and your experience.

HAZARD

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN Attempting stunts increases the chance of an accident, including

an overturn. HOW TO AVOID THE Never attempt wheelies, jumps, or other stunts. Avoid exhibition

driving.

HAPPEN

HAZARD

Operator Safety

WARNING

POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN Poor maintenance increases the possibility of an accident or

equipment damage. HOW TO AVOID THE Always inspect your A TV before each use to make sure it’s in

safe operating condition. Always follow the inspection and maintenance procedures and

schedules described in the owner’s manual.

HAPPEN

HAZARD

WARNING

SAFETY

POTENTIAL Removing hands from the handlebars or feet from the

footrests during operation. WHAT CAN Removing even one hand or foot can reduce ability to

control the vehicle or could cause loss of balance and ejection from the A TV.

If the operator’s foot is not firmly planted on the footrest, it could come into contact with the rear wheels and lead to accident or injury .

HOW TO AVOID THE Always keep both hands on the handlebars and both feet

on the footrests of the ATV during operation.

HAZARD

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar

terrain. WHAT CAN Unfamiliar terrain may contain hidden rocks, bumps, or holes that

could cause loss of control or overturn. HOW TO AVOID THE Travel slowly and use extra caution when operating on unfamiliar

terrain. Always be alert to changing terrain conditions.

HAPPEN

HAZARD

Operator Safety

WARNING

POTENTIAL HAZARD Failure to use extra caution when operating on excessively

rough, slippery or loose terrain. WHAT CAN Operating on excessively rough, slippery or loose terrain could

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

HOW TO AVOID THE Do not operate on excessively rough, slippery or loose terrain

until you’ve learned and practiced the skills necessary to control the A TV on such terrain.

Always use extra caution on rough, slippery or loose terrain.

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Turning improperly. WHAT CAN Improper turns could cause loss of control and lead to a collision

or overturn. HOW TO AVOID THE Always follow proper procedures for turning as described in the

owner’s manual. Practice turning at slow speeds before attempting to turn at

faster speeds. Never turn at excessive speed.

HAPPEN

HAZARD

WARNING

POTENTIAL Operating on excessively steep hills. WHAT CAN The vehicle may overturn. HOW TO AVOID THE Never operate on hills too steep for the ATV or for your

abilities. Never operate the ATV on hills steeper than 25_. Practice on smaller hills before attempting large hills.

HAZARD

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Climbing hills improperly. WHAT CAN Improper hill climbing could cause loss of control or overturn. HOW TO AVOID THE Always follow proper procedures for climbing hills as described

in the owner’s manual. Always check the terrain carefully before ascending any hill. Never operate the ATV on hills steeper than 25_. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly while traveling uphill. The A TV

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

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

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Traveling downhill improperly. WHAT CAN Improperly descending a hill could cause loss of control or

overturn. HOW TO AVOID THE 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

68. Always check the terrain carefully before you descending a hill. Shift your weight backward. 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.

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Improperly crossing hills and turning on hills. WHAT CAN Improperly crossing or turning as hills could cause loss of control

or overturn. HOW TO AVOID THE 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 69. Use extra caution when turning on any hill.

Avoid crossing the side of a steep hill. When crossing the side of a Always follow proper procedures as described in the owner’s

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

HAPPEN

HAZARD

hill:

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Stalling, rolling backwards or

improperly dismounting while climbing a hill.

WHAT CAN The vehicle could overturn. HOW TO AVOID

HAZARD Maintain steady speed when

climbing a hill. If all forward speed is Keep your weight uphill. Apply the single lever brake gradually. When fully stopped, apply the auxiliary rear brake as well, then

lock the parking brake. If the A TV begins rolling Keep weight uphill. Never apply engine power. Never apply the auxiliary rear brake while rolling backwards. Apply the single-lever brake gradually. When fully stopped, apply the auxiliary 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 69.

HAPPEN

THE

lost:

backwards:

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN Operating over obstacles could cause loss of control or overturn. HOW TO AVOID THE Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen

trees when possible. If unavoidable, use extreme caution and always follow proper procedures as outlined in the owner’s manual.

HAPPEN

HAZARD

WARNING

POTENTIAL Skidding or sliding. WHAT CAN Skidding or sliding can cause loss of control. If the tires regain traction unexpectedly, the ATV could overturn. HOW TO AVOID THE On slippery surfaces such as ice, travel slowly and use extra

caution to reduce the chance of skidding or sliding out of control.

HAZARD

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

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

which could lead to an accident or overturn. HOW TO AVOID THE 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 70), travel slowly, balance your weight carefully, avoid sudden movements, and 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. Always test the brakes after leaving water. If necessary, apply them several times to let friction dry out the pads.

HAPPEN

HAZARD

WARNING

POTENTIAL Improperly operating in reverse. WHAT CAN The ATV could collide with an obstacle or person, resulting in

severe injury. HOW TO AVOID THE Before shifting into reverse gear, always check for obstacles or

people behind the ATV. When it’s safe to proceed, back slowly.

HAZARD

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating this ATV with improper tires, or with improper or uneven

tire pressure.

WHAT CAN

Use of improper tires, or operation of the ATV with improper or

uneven tire pressure, could cause loss of control or accident.

HOW TO AVOID THE

Always use the size and type of tires specified in the owner’s

manual supplement for the ATV.

Always maintain proper tire pressure as described in the owner’s

manual supplement.

HAPPEN

HAZARD

WARNING

POTENTIAL

Operating the ATV with improper modifications.

WHAT CAN

Improper installation of accessories or modification of the ATV

may cause changes in handling which could lead to an

accident.

HOW TO AVOID THE

Never modify the ATV through improper installation or use of

accessories. All parts and accessories added to the vehicle

must be genuine Polaris Industries Inc. or equivalent

components designed for use on this ATV and should be

installed and used according to approved instructions. See

your authorized Polaris A TV dealer for more information.

HAZARD

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Overloading the A TV or carrying/towing cargo improperly . WHAT CAN Overloading and towing can cause changes in vehicle handling,

which could lead to loss of control or an accident. HOW TO AVOID THE Never exceed the stated load capacity for this ATV . Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow a

greater distance for braking. Always follow the instructions in the owner’s manual for carrying

cargo or pulling a trailer. See page 61.

HAPPEN

HAZARD

WARNING

POTENTIAL Operating on frozen bodies of water. WHAT CAN Severe injury or death can result if the ATV and/or the operator

fall through the ice. HOW TO AVOID THE Never operate the ATV on a frozen body of water. If you’re

confident that the ice is thick enough and sound enough to support the machine and its operator, as well as the force created by a moving vehicle, exercise extreme caution.

HAZARD

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

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

WARNING

After any overturn or accident, have a qualified service dealer inspect the entire vehicle for possible damage, including (but not limited to) brakes, throttle and steering systems.

WARNING

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

CAUTION

Always keep combustible materials away from the exhaust system. Exposure to the hot components could result in a fire.

SAFETY

Safety Decals and Locations

Warning decals have been placed on the ATV for your protection. Read and follow the instructions on each decal carefully. If a decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal.

WARNING

DNever operate this vehicle on HILLS steeper than 25 degrees

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

REVERSE operation can be dangerous, even at low

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

DUse OVERRIDE for reverse speed limiter with caution.

To prevent loss of control, never acti vate override button with open throttle.

DPARKING BRAKE may relax when used for more than

5 minutes. When parking on grades, leave shift in forward.

7079085

Non-drum shift models

WARNING

DNever operate this vehicle on HILLS steeper than 25 degrees

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

REVERSE operation can be dangerous, even at low

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

DUse OVERRIDE for reverse speed limiter with caution.

To prevent loss of control, never acti vate override button with open throttle.

DWhen this ATV is not in operation, or unattended,place

shift in park position.

7171383

Drum shift models

WARNING

This ATV may exceed the performance of other ATVs you may have ridden in the past. This category S (Sport) ATV is a high performance vehicle for off road use only, in sport type recreation and competitive use by operators with advanced skills and substantial experience.

25°.

WARNING

IF OWNER’S MANUAL IS MISSING, CONTACT

A P OLARIS DEALER FOR A REPLACEMENT.

E1997, 2000

7079083

Trail Blazer models

Safety Decals and Locations

SAFETY

WARNING

Operating this vehicle if you are under the age of 16 increases y our chance ofsevere injury or death.

NEVER operate this vehicle if you are under age 16.

WARNING

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

TIRE PRESSURE (PSI): FRONT ___ REAR ___

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

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

Read Owner’s Manual for more detailed loading information

See your Owner’s Manual Supplement for specifications.

SAFETY

Safety Decals and Locations

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 hitc h.

Maximum Rack Loads: Front 90 lbs. Rear 180 Lbs

On models with racks

WARNING

7170021

Moving parts hazard under belt-clutc h 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

DOperation of this

vehicle without the filter element will severely damage the engine.

DClean air filter often, more

frequent cleaning required in dusty conditions

ATTENTION

DSpecific carburetor jetting

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

Under Seat

7078689

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

Factory setting:

C. at 0-900 meters).

7079901

Safety Decals and Locations

SAFETY

WARNING

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

7079604

AWD Models

ALL WHEEL

DRIVE

SWITCH

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

7079780

Chain Freeplay Is Important.

OVERRIDE

SWITCH

Reverse Speed is limited.

Reverse override is controlled by the override switch.

See your Owner’s Manual.

7079906

2WD Models

MANUFACTURED BY: POLARIS IND

DATE:

VIN:

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

CE VÉHICULE EST UN VÉHICULE TOUT TERRAIN QUI NiEST PAS DESTINÉ À ÊTR E UTILISÉ SUR LES CHEMINS PUBLICS.

PRINTED IN U.S.A.

Canadian Certification Decal

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

Torque Nut on Eccentric Bolts: To 30 Ft. Lbs.(For models without a hitc h). To 60 Ft. Lbs. (For models with ahitch.

7078572

7077185

NOTE: Y our ATV will not have all of the decals shown on this page. Decals vary depending on the model you own.

SAFETY

Safe Riding Gear

Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury.

1. Helmet

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

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

2. Eye Protection

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

3. Gloves

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

4. Boots

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

5. 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.

Electrical Switches

CONTROLS

WARNING

Activating the override switch while the throttle is open can cause loss of control, resulting in severe injury or death. Do not activate the override switch while the throttle is open.

Override Switch (1) (Reverse Speed Limiter) - This vehicle is equipped with a reverse speed limiter

RUN

OFFOFF

system. To gain additional power while backing, depress the override switch. NOTE: The override switch also allows activation of Demand 4 Drive

(All Wheel Drive) in reverse, if the Demand 4 Drive switch is on.

Main Switch (2) - To start the engine, slide the stop switch to the center “run” position and turn the main key switch clockwise past the “on” position. Release the key when the engine starts. NOTE: Turn off the main switch to end all electrical power to the vehicle, including the cooling fan and lights.

WARNING

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

Engine Stop Switch (3) - The engine will not start or run when the switch i s in its “off” position. Its purpose is to provide the operator with a quick means of engine shutdown in case of an emergency. To stop the engine, slide the stop switch either right or left to the “off” position. NOTE: Turning off the engine stop switch will shut off all electrical power to the vehicle, with the exception of the cooling fan on some models. On those models, use the main switch to shut off the power to the cooling fan.

CONTROLS

WARNING

Do not start or operate an ATV with sticking or improperly operating throttle controls, which could cause an accident and lead to severe injury or death.

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

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.

Throttle Lever

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

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

WARNING

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

CONTROLS

WARNING

Operating the ATV on streets or roads, especially in darkness, could result in an accident and serious injury or death.

Your ATV is not equipped with highway-approved lights. It’s designed for and must be used for off-road use only . Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness.

Light Switches

The light switch is located on the left handlebar (1). It’ s used to turn the lights on and off and to switch the lights from HI to LO on models equipped with HI-LO beams. NOTE: The lights won’t work unless the key is in the “on” position and the shut-off switch i s in the “run” position.

Brakes

Check the brake fluid level in the master cylinder before each use of the ATV. The master cylinder (2) is located on the left handlebar.

The fluid level can be seen through an indicator window (3) on the top of the master cylinder. This “eye” will appear dark when the fluid level is full. When fluid needs to be added, the eye will be clear.

NOTE: When checking the fluid level, the ATV must be on level ground with the handlebars straight. If the fluid level is low add DOT 3 brake fluid only. See page 141 for the part numbers of Polaris-recommended products.

WARNING

After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. 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 accident or severe injury.

CONTROLS

Brake Lever

The front and rear brakes are applied by squeezing the brake lever (1) toward the handlebar. The front and rear brakes are hydraulically activated disc type brakes that are activated by only one lever.

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

WARNING

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.

CONTROLS

Parking Brake

WARNING

Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death.

Always check to be sure the parking brake is disengaged before operating.

Setting the Parking Brake

1. Squeeze and release the brake

lever (1) two or three times, then

squeeze and hold.

2. Push the park brake lock (2)

forward to engage the brake.

Release the brake lever.

3. To release the parking brake lock,

squeeze and release the brake

lever. It will return to its unlocked

position.

Important Safeguards

S The parking brake may relax if left on for a long period of time. Al-

ways block the wheels t o prevent rolling.

S 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.

S Never depend on the parking brake alone if the ATV is parked on a

hill. Always block the wheels to prevent rolling.

CONTROLS

Auxiliary Brake

WARNING

Aggressively applying the rear 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 (1), is located on the inside of the right floor board and is operated by the right foot. The auxiliary brake serves as a backup to the main brake system if the main system becomes inoperative.

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

Check the brake fluid level frequently for the auxiliary brake system. The reservoir is located under the seat or near the foot brake. Maintain the fluid level between the maximum and minimum marks.

CONTROLS

Choke

The choke assists in starting a cold engine. Refer to the engine starting procedure on page 59 for correct choke and throttle settings during starting.

Fuel Valve

The fuel valve (1) is located on the left side of the vehicle, either below the fender or on the side panel. It has three positions:

OFF: For vehicle storage and when transporting.

ON: For normal operation.

RES: For reserve supply if main supply is exhausted.

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

Always return valve to “on” position after refueling.

OFF

Fuel Tank

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

Fuel Filter

The i n-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.

RES

CONTROLS

Fuel Safety

WARNING

Gasoline is highly flammable and explosive under certain conditions.

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

well ventilated area.

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

area where refueling is performed or where gasoline is stored.

S Do not overfill the tank. Do not fill the tank neck. S If gasoline spills on your skin or clothing, immediately wash it

off with soap and water and change clothing.

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

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

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

WARNING

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.

CONTROLS

Oil Injection Tank - 2-Cycle Models

CAUTION

Mixing brands or using a non-recommended oil may cause serious engine damage. We recommend the use of Polaris Premium Synthetic 2-cycle oil for your 2-cycle Polaris ATV. Never substitute or mix oil brands.

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

Models with 2-cycle engines have oil injection. The oil injection tank filler cap (1) is located on the front of the vehicle. Tank capacity is two quarts (1.9 l.).

CONTROLS

Automatic Transmission Gear Selector

The t ransmission gear selector (1) is located on the right side of the vehicle. Shift patterns vary, depending on your model.

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

CAUTION

Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage.

To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear.

Whenever the ATV is left unattended, always place the transmission in gear with the parking brake locked.

Maintaining shift linkage adjustment is important to assure proper transmission function. S ee your dealer if you experience any shifting problems.

Belt Life

T o extend belt life, use low forward gear in heavy pulling situations and when operating at less than seven miles per hour for extended periods of time.

CONTROLS

Recoil Starter

If the battery is weak and cannot start the engine, use of the recoil starter (1) will allow vehicle operation until repairs can be made. The recoil starter is located on the right side of the machine.

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

1. Position the vehicle on a level surface and engage the parking

brake. See page 41.

2. Shift the transmission to Neutral.

3. Grasp the recoil starter rope handle tightly and pull slightly until

the starter mechanism engages.

4. Pull the rope abruptly to start the engine.

CAUTION

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

If the starter rope handle is not seated properly, water may enter the recoil housing and damage components. Make sure the handle is fully seated on the recoil housing, especially when traveling in wet areas.

FEATURES

All Wheel Drive (AWD) System

Polaris 4 wheel drive ATVs are equipped with a unique, Polaris exclusive, Demand 4 Drive (AWD) system that’ s activated by a switch (1) on the right handlebar. When the switchisoff,theATVisin2wheel drive at all times. When the switch is on, the ATV is in Demand 4 Drive and the AWD i ndicator light (2) will be on.

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

NOTE: The override switch allows activation of Demand 4 Drive (AWD) in reverse if the Demand 4 Drive switch is on. See page 37.

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

Engaging Wheel Hubs

The Demand 4 Drive 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 front hubs are moving, the hubs will not disengage until the rear wheels regain traction.

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

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

CAUTION

Switching to AWD while the rear wheels are spinning may cause severe drive shaft and hub damage.

Always switch to AWD while the rear wheels have traction or are at rest.

FEATURES

All Wheel Drive (AWD) System

Disengaging Wheel Hubs

Although the hubs normally disengage when operating in reverse, one or both hubs may occasionally remain engaged. If the handlebars pull to one side, it’s likely that one front hub is engaged . If both hubs are engaged, steering effort increases but remains balanced from left to right, and vehicle speed is somewhat restricted.

Disengage the hubs by stopping, shifting to reverse, and backing for a short distance. Then proceed in forward again.

NOTE: If the hubs remain engaged after following this procedure, return the ATV to your dealer for service.

To continue using AWD in reverse, activate the override switch and the Demand 4 Drive switch. See page 37.

WARNING

Operating with only one front hub engaged could result in loss of control, accident, and severe injury or death.

When hub engagement symptoms are present, use the disengaging procedure before proceeding.

FEATURES

Indicator Lights

The configuration of the indicator lights differs with individual models. Not every model is equipped with all of the lights, and the lights on some models appear in the speedometer. The information in your owner’s manual supplement and on this page will help you identify the lights and their function.

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

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

1. Transmission Neutral Indicator (green)

2. Transmission Low Gear Indicator (blue/grey)

3. Transmission Reverse Indicator (yellow)

4. Oil Warning (red) On 2-cycle models, this light indicates a low oil level.

5. HighTempWarning(red) This light will display if the engine overheats.

6. All Wheel Drive Indicator (red) See page 48 for more information about AWD.

7. High Beam Indicator (blue)

FEATURES

Instrument Cluster

Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. 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. Refer to page 37 for additional i nformation.

1. Rider Information Center

2. Speedometer needle - in addition to depicting vehicle speed, this

needle will flash to signal a fault condition.

3. Speedometer

CAUTION

Washing the ATV with a high pressure washer may cause water to enter the instrument cluster and cause damage to the electronic components. Wash the ATV by hand or with a garden hose using mild soap. Do not use alcohol to clean the instrument cluster. Immediately clean off any gasoline that splashes on the instrument cluster.

FEATURES

Instrument Cluster

Rider Information Center

The rider information center is located in the lower portion of the instrument cluster.

1. Gear Indicator - As the

shift lever is moved, this will indicate the gear the machine is in:

H = High Range

L = Low Range

N = Neutral

R = Reverse

P=Park

Eorblank=Error-The error message usually means the gear selector is in between gears. It can, however, also indicate that the transmission switch needs repair.

2. High Engine Coolant Temperature - Do not continue to operate the

ATV is this warning appears or serious engine damage could result.

3. Hour Meter

4. Service Interval/Miscellaneous Service Warnings

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

that the ATV is being operated at an RPM too low to keep the

battery charged. Driving at a higher RPM or connecting a battery

charger will usually clear the warning. NOTE: All segments of the rider information center will light up for

2.5 seconds at start-up.

FEATURES

Instrument Cluster

Rider Information Center

The rider information center has 4 standard modes: Mode 1 - Odometer Mode 2 - Tripmeter Mode 3 - Total Service Hours Mode 4 - Programmable service interval The reverse override button on the left handlebar is also the mode

button. NOTE: If using the mode button to program the rider information center, or to toggle through the options, the machine cannot be in reverse.

Mode 1 - Odometer

The odometer records the miles traveled by the ATV.

Mode 2 -Trip Meter

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

Mode 3 - Hour Meter

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

FEATURES

Instrument Cluster

Rider Information Center

Mode 4 - Programmable Service Interval

The purpose of the programmable service interval is to provide the consumer and dealer with a convenient reminder for routine maintenance. When your vehicle leaves the factory, this feature is turned off. You must enable the programmable service interval before it can be used.

Once the service interval mode is set with the hours when service is due, the hours of actual engine operation are subtracted from t he set hours until 0 is reached. When the counter reaches 0, the wrench icon will flash quickly for 5 seconds each time the vehicle is started as a reminder that the periodic maintenance is due.

To set the hours, press and hold the mode/override button until the wrench icon flashes. When it begins to flash, release t he button. The setting will increase by one hour each time the button is pressed. Pressing and holding the button will allow the numbers to escalate much faster. When the desired time increment is displayed, release the button and wait for the wrench to stop flashing. When the wrench stops blinking, your service hours are set. NOTE: If you scroll past the intended number, hold the button down until the count turns over to

0. You can then reset the number. If the service interval is enabled on your ATV and you wish to turn it

off, toggle to the service interval mode. Press and hold the mode button for approximately 7 seconds until the word OFF appears in the Rider Information Center.

FEATURES

Instrument Cluster

Rider Information Center

Diagnostic Mode

The diagnostic mode is for informational purposes only. Please return your ATV to your dealer for all major repairs.

To enter the diagnostics mode:

1. Turn the key switch off and wait 20 seconds.

2. Set the park brake and shift the transmission to neutral.

3. Hold the mode/reverse override button and turn the key switch on. The i nitial screen displayed looks

similar to the top illustration and refers to the software version installed in your ATV. This information is displayed briefly.

Use the mode/reverse override button to toggle through the diagnostic screens. The first screen (1) displays battery voltage.

The second screen (2) provides full diagnostics for the entire oil pressure electrical circuit. Along with the letters PrSSr, there will be a box on the left side. If the box is high, the pressure is normal. If the box is low, the pressure is low.

Screen three (3) is the tachometer for setting idle speed. If this needs adjustment, please contact your dealer.

As long as the center is in the diagnostic mode, the wrench icon will remain lit.

To leave the diagnostic mode, either shift the machine out of neutral or turn the key switch off and on. NOTE: Any movement of the tires will also take the machine out of the diagnostic mode.

OPERATION

Break-In Period

2-Cycle Engines

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

CAUTION

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

Use of any oils other than those recommended by Polaris may cause serious engine damage. We recommend the use of Polaris 2-cycle oil for your 2-cycle engine.

Lack of proper lubrication will cause serious engine damage. Always fill the oil tank when refueling the ATV.

The first tank of fuel must be pre-mixed according to the following instructions. After the break-in period, the oil injection system will provide the necessary engine lubrication without pre-mixing.

1. Mix 12.8 ounces of Polaris 2-cycle oil to four gallons (or 16

ounces to five gallons) of gasoline in a suitable gas container. Fill

the fuel tank. See page 43.

2. Fill the oil tank with Polaris 2-cycle oil.

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

familiarize yourself with vehicle operation and handling.

4. Vary the throttle positions.

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

on the daily pre-ride inspection checklist. See page 58.

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

OPERATION

Break-In Period

4-Cycle Engines

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

CAUTION

Use of any oils other than those recommended by Polaris may cause serious engine damage. We recommend the use of Polaris Premium 4 Synthetic Oil for your 4-cycle engine.

1. Fill the fuel tank with gasoline. See page 43.

ADD 8 OZ. NORMAL FULL

2. Check the oil level on the dipstick. See page

98. Add Polaris Premium 4 Synthetic Oil if necessary to maintain the oil level in the normal (safe) operating range (1).

3. Drive slowly at first. Select an open area that allows room to familiarize yourself with vehicle operation and handling.

4. Vary 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 58.

6. Pull only light loads.

7. During the break-in period, change both the oil and the filter at 20 hours or 200 miles.

OPERATION

Pre-Ride Inspection

WARNING

If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it’s in proper operating condition.

Use the following checklist t o verify that your vehicle is in proper working condition before each use.

Item/Inspection Procedure

1. Tires - Check condition and pressures.

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

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

4. Throttle - Check for free operation and closing.

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

6. Engine stop switch - Check for proper function.

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

8. Drive chain - Check condition and slack (refer t o drive chain adjustment section); lubricate when needed.

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

10. Steering - Check for free operation, noting any unusual looseness in any area.

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

12. Riding gear - Wear a helmet, goggles and protective clothing.

13. Engine coolant (liquid cooled models) - Check for proper level at the recovery bottle.

OPERATION

Starting the Engine

Starting a Cold Engine

WARNING

Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area.

CAUTION

Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating the vehicle.

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

2. Turn the fuel tank valve on.

3. Sit on the vehicle.

4. Pull the choke knob out until it stops (1).

NOTE: 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.

5. Turn the engine stop switch to “run”.

NOTE: Do not press the throttle while starting the engine.

6. Turn the ignition key past the “on” position to engage the starter. Activate the starter for a m aximum of five seconds, releasing the key when the vehicle starts. If the engine does not start, release the starter and wait five seconds. Then activate the starter for another five seconds. Repeat this procedure until the engine starts.

7. If the engine slows or stops, position the choke knob half way in to allow proper engine warm up.

8. Vary the engine RPM slightly with the throttle to aid in warm-up. When the engine idles smoothly, push the choke all the way in.

OPERATION

Starting the Engine

Starting a Warm Engine

Warm engines do not normally require the use of the choke. Using the choke can cause the spark plug to become wet fouled.

1. Position the vehicle on a level surface with the transmission in neutral.

2. Lock the parking brake, turn the fuel tank valve to “on”, sit on the vehicle, and turn the engine stop switch to “run”.

3. If the engine has cooled to a point where it does not readily start, intermittent use of the choke button (pulled half way out) may be necessary.

4. If the engine is over-choked when warm, depress the throttle lever fully while cranking to aid in starting.

5. Release the throttle lever immediately after the engine starts. If the engine does not start and all conditions are favorable, change the sparkplugandtryagain.

Cold Weather Operation for 4-Cycle Engines

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

See your Polaris dealer for engine heater kits, which provide quicker warm-ups and easier starting in colder weather.

Hauling Cargo

OPERATION

2/3

Your ATV has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warnings listed on the warning labels, and never exceed the weights specified in your owner’s manual supplement.

Cargo weight should be evenly distributed (1/3 on the front and 2/3 on the rear) and mounted as low as possible. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions.

Maximum Towing Capacities

Refer to your owner’s manual supplement for model specific towing capacities. When towing, reduce the rear rack cargo load capacity by the amount of trailer tongue weight.

Never tow any trailer on a grade steeper than 15°.

Belt Life

Use low forward gear when hauling or towing heavy cargo to extend belt life.

1/3

OPERATION

Hauling Cargo

WARNING

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

S REDUCE SPEED AND ALLOW GREATER DISTANCE FOR

BRAKING WHEN HAULING CARGO.

S CARGO WEIGHT DISTRIBUTION should be 1/3 on the front

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

S LOADS MUST BE CARRIED AS LOW ON THE RACKS AS

POSSIBLE. Carrying loads high on the racks raises the center of gravity of the vehicle and creates a less stable operating condition. When cargo loads are carried high on the racks, the weight of the loads must be reduced to maintain stable operating conditions.

S ALL LOADS MUST BE SECURED BEFORE OPERATING. Un-

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

S OPERATE ONLY WI TH STABLE AND SAFELY ARRANGED

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

S HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROB-

LEMS. Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations that may require backing downhill.

S EXTREME CAUTION MUST BE USED when operating with

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

S DO NOT BLOCK T HE FRONT HEADLIGHT BEAM when carry-

ing loads on the front rack.

S DO NOT TRAVEL FASTER THAN THE RECOMMENDED

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

OPERATION

Driving Safely

Driving Procedures

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

2. Start the engine and allow it to warm up, then shift the transmission into gear.

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

4. Release the parking brake.

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

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

OPERATION

Driving Safely

Making Turns

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

To make a 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.

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

WARNING

Turning at sharp angles or at excessive speeds can result in vehicle overturn and lead to serious injury. Avoid turning at sharp angles. Never turn at high speeds.

OPERATION

Driving Safely

Driving on Slippery Surfaces

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

1. Slow down when entering slippery areas.

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

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

4. Drivingwith Demand4 Drive (All Wheel Drive) engaged can assistin controlling the vehicle in slippery areas.

CAUTION

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

WARNING

Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control, accident, and serious injury or death.

Never apply the brakes during a skid. Do not operate on excessively slippery surfaces. Always reduce speed and use additional caution.

OPERATION

Driving Safely

Driving Uphill

Whenever traveling uphill, follow these precautions:

1. Always travel straight uphill.

2. Avoid steep hills (25_ maximum).

3. Keep both feet on the footrests.

4. Transfer your weight forward.

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

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

If all forward speed is lost:

Keep your weight uphill. Apply the single lever brake, gradually. When fully stopped, apply the

auxiliary brake as well, then lock the park brake.

If the ATV begins rolling backwards:

Keep your weight uphill. Never apply engine power. Never apply the auxiliary rear brake while rolling backwards.

Apply the single-lever brake, gradually. When fully stopped, apply the auxiliary rear brake as well, and then lock the parking brake.

Dismount on uphill side, or t o either side if ATV is pointed straight uphill. Turn the ATV around and remount, following the procedure described on page 69.

25_ Maximum

WARNING

Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn and result in serious injury or death.

Avoid climbing steep hills (25_ maximum). Use extreme caution when operating on hills, and follow proper

operating procedures outlined in the owner’s manual.

OPERATION

Driving Safely

Sidehilling

WARNING

Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner’s manual.

Sidehilling can be a dangerous type of driving and should be avoided if at all possible. If you do enter into a situation where sidehilling is necessary, follow these precautions:

1. Slow down.

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

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

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

OPERATION

Driving Safely

Driving Downhill

Whenever descending a hill, follow these precautions:

1. Proceed directly downhill.

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

3. Slow down.

4. Apply the brakes slightly to aid in slowing, using the single brake lever.

NOTE: Familiarize yourself with operation of the auxiliary rear brake pedal for additional braking in the event of normal service brake loss.

WARNING

Excessive speed can cause loss of control and lead to serious injury or death. Always operate slowly when traveling downhill.

OPERATION

Driving Safely

Turning Around on a Hill

WARNING

Improper hill climbing procedures could cause loss of control or overturn and result in serious injury or death.

Avoid climbing steep hills (25_ maximum). Use extreme caution when operating on hills, and follow proper

operating procedures outlined in the owner’s manual.

If the vehicle stalls while climbing a hill, never back it down the hill! One maneuver that can be used when it’s necessary to turn around while climbing a hill is the K-turn:

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

2. Leave 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 and remount the vehicle from the uphill side, keeping body weight uphill.

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

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

8’

Uphill

OPERATION

Driving Safely

Driving Through Water

Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests (1). Follow these procedures when operating through water:

1. Determine water depths and current before crossing.

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

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

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

After running the vehicle in water, it’s critical to have it serviced as outlined in the maintenance chart. See page 75. The following areas need special attention: engine oil, transmission oil, front and rear gearcases, and all grease fittings.

CAUTION

Major engine damage can result if the vehicle is not thoroughly inspected after operation in water. Perform the services outlined in the maintenance chart.

If your vehicle becomes immersed or is operated in water that exceeds the footrest level, take it to your dealer for service before starting the engine.

NOTE: Avoid operating the vehicle through deep or fast-flowing water . If you cannot avoid water that exceeds the recommended maximum depth, go slowly, balance your weight carefully, avoid sudden m ovements, and maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make sudden throttle changes.

If your vehicle becomes immersed, and it’s impossible to take it to a dealer before starting it, follow the steps described on page 127. Have the vehicle serviced by your dealer at the first opportunity.

OPERATION

Driving Safely

Driving Over Obstacles

Be alert! Look ahead and learn to read the terrain you’re traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches.

WARNING

Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. Not all obstacles are immediately visible. Travel with caution in unfamiliar terrain.

OPERATION

Driving Safely

Driving in Reverse

Follow these precautions when operating in reverse:

1. Always avoid backing downhill.

2. Back slowly.

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

4. Avoid turning at sharp angles in reverse.

5. Never open the throttle suddenly while backing.

WARNING

Failure to use caution when operating in reverse can result in serious injury or death. Before shifting into reverse, always check for obstacles or people behind the vehicle. When it’s safe to proceed, back slowly.

Do not use the override switch unless additional power is required for vehicle movement. Use with caution.

Avoid backing on inclines, and avoid turning at sharp angles.

NOTE: Most Polaris ATVs are equipped with a reverse speed limiter. The override button should be used with caution as rearward vehicle speed is greatly increased. Do not operate at wide open throttle. Open the t hrottle just enough to maintain a desired speed.

CAUTION

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

Driving Safely

ParkingonanIncline

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

1. Turn the engine off.

1. Place the transmission in gear.

2. Set the parking brake.

3. Always block the rear wheels on the downhill side. See illustration.

4. Shut off the fuel supply.

NOISE EMISSION CONTRO L SYSTEM REGULATION

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED!

U.S. Federal law prohibits the following acts or the causing thereof:

(1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or

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

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

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

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

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

4. Lack of proper maintenance.

CAUTION

Exhaust system components are very hot during and after use of the vehicle. Hot components can cause serious burns and can causeafiretoignite.

Do not touch hot exhaust system components. Use caution when traveling through tall grass, especially dry

grass.

USFS Approved Spark Arrestor

Most Polaris ATVs have mufflers t hat were tested and approved in accordance with the USFS Forest Service Standard 5100-1A. Refer to your owner’s manual supplement for model specific information.

MAINTENANCE AND LUBRICATION

Accessories

Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights. Accessory outlets are available for all models. Contact your Polaris dealer for more information.

Polaris has a wide range of additional accessories available for your ATV. See your Polaris dealer.

Periodic Maintenance Schedule

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 schedule.

Some models are equipped with a speedometer that has a programmable service interval mode. This important feature will help you determine when maintenance service is due. See page 54 for instructions.

Maintenance intervals in the following charts are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use, such as operation in wet or dusty areas, should be inspected and serviced more frequently.

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.

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

Maintenance Chart Key

" Perform these operations more often under severe use, such as in

dirty or wet conditions, to purge water or dirt contamination from grease fittings and other critical components.

L Emission Control System Service (California - 4-Cycle) NOTE: Some 4-Cycle models may have an additional California

-only emissions warranty. Please refer to your owner’s manual supplement for model specific information.

J Dealer service item.

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Hours of operation are based on a 10 mph average. If service is due at 20 hours, the equivalent odometer reading would be 200 miles. Perform all services at whichever reading is reached first.

WARNING

Improperly performing the procedures marked with a J could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services.

Item Hours/

Miles

Brake System Pre-Ride Pre-Ride Inspect Auxiliary Brake Pre-Ride Pre-Ride Inspect Tires Pre-Ride Pre-Ride Inspect Wheels Pre-Ride Pre-Ride Inspect Frame nuts, bolts,

fasteners Oil level (2-Cycle) Pre-Ride Pre-Ride Check when refueling

Air filter, Pre-cleaner

Coolant level Pre-Ride Pre-Ride Replace coolant every two

Fuel and oil tanks Pre-Ride Pre-Ride Fill to proper levels Throttle Pre-Ride Pre-Ride Check operation Lights Pre-Ride Pre-Ride Check operation Engine stop switch Pre-Ride Pre-Ride Check operation Drive chain Pre-Ride Pre-Ride Check condition/slack Steering Pre-Ride Pre-Ride Check for free operation

" Air box sediment

tube Headlamp Pre-Ride Pre-Ride Check operation daily; ap-

Pre-Ride Pre-Ride Inspect

Pre-Ride Pre-Ride Inspect; clean

Pre-Ride Pre-Ride Drain deposits whenever

Frequency Remarks

years

visible

ply Polaris dielectric grease to connector when replaced

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item Hours/

Miles

Taillight/brakelight Pre-Ride Pre-Ride Check operation daily; ap-

Air filter, main element

" Transmission oil

level Battery 20 hrs Monthly Check terminals; clean;

Engine counterbalance (400 Engines)

Engine breather filter (4-cycle)

J Brake pad wear 10 hrs Monthly Inspect periodically " Front and rear

gearcase oil (shaft drive)

Engine cylinder head and cylinder base fasteners

" General lubrication 50 hrs 3 months Lubricate all fittings, pivots,

Engine oil level/oil change (4-Cycle)

Oil Filter(4-Cycle) 100 hrs./

Oil Pump Cable (2-Cycle)

Engine breather

hose (4-cycle)

Weekly Weekly Inspect; replace as needed

20 hrs Monthly Inspect monthly; change

20 hrs Monthly Check oil level; change

20 hrs Monthly Inspect; replace annually

100 hrs Monthly Check monthly; change

25 hrs 3 months Inspect (re-torque required

100 hrs / 1000 miles

1000 mi. 50 hrs. 6 months Inspect, adjust, lubricate,

100 hrs. 6 months Inspect

Frequency Remarks

ply Polaris dielectric grease to socket when replaced

annually

check fluid level

annually

and as needed

annually

at first service only)

cables, etc.

6 months Check level daily; break-in

service at one month; change oil more often in cold weather

6 months Replace with oil change

replace if required

" More often under severe use, such as dirty or wet conditions

L Emission Control System Service (California)

J Dealer service item

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

WARNING

Improperly performing the procedures marked with a J could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services.

Item Hours/

Miles

Carburetor float bowl

J Throttle Cable/ETC

Switch Choke (enricher)

cable Coolant strength/

pressure test system

" Front hubs/fluid

check (AWD) Shift linkage 50 hrs. 6 months Inspect; adjust

J Drive belt 50 hrs. 6 months Inspect; replace as needed " Steering 50 hrs. 6 months Inspect daily; lubricate " Front suspension 50 hrs. 6 months Inspect; lubricate; tighten

" Rear suspension 50 hrs. 6 months Inspect; tighten fasteners " Drive chain(s) 50 hrs. 6 months Inspect daily; adjust and lu-

Spark plug 100 hrs. 12 months Inspect; replace as needed

" Rear axle 50 hrs. 6 months Inspect bearings; lube

Ignition Timing 100 hrs. 12 months Inspect; adjust as needed

50 hrs. 6 months Drain bowl periodically and

50 hrs. 6 months Inspect; adjust; lubricate;

100 hrs. 6 months Inspect strength seasonal-

50 hrs. 6 months Check monthly

Frequency Remarks

prior to storage

replace if necessary

ly; pressure test system annually

fasteners

bricate if needed

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item Hours/

Miles

Fuel system 100

J Fuel filter 100 hrs. 12 months Replace annually

Radiator 100 hrs. 12 months Inspect; clean external sur-

Cooling system hoses

Spark arrestor 100 hrs. 12 months Clean out

" Front hubs (AWD) 100 hrs. 12 months Change fluid annually J Clutches (drive and

driven) Engine mounts 100 hrs. 12 months Inspect

Valve clearance (4-Cycle)

J Oil filter (2-Cycle) 100 hrs. 12 months Replace J Shift selector box

(H/L/R)

J Brake fluid 200 hrs. 24 months Change every two years J Front wheel bear-

ings (2WD) Idle speed As required Adjust

Recoil housing As required Drain moisture out after rid-

J Toe adjustment As required Periodic inspection; adjust

Headlight aim As required Adjust as needed

hours

100 hrs. 12 months Inspect

100 hrs. 12 months Inspect; clean

100 hrs. 12 months Inspect; adjust

200 hrs. 24 months Change lubricant every two

300 hrs. 36 months Inspect; replace as needed

Frequency Remarks

12 months Check for leaks at tank

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

face

years

inginwater

when parts are replaced

" More often under severe use, such as dirty or wet conditions

L Emission Control System Service (California)

J Dealer service item

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

NOTE: Hours are based on 10 mph average. If service is due at 20 hours, the equivalent odometer reading would be 200 miles. Perform all services at whichever reading is reached first.

Lubrication Chart Key

" More often under severe use, such as wet or dusty conditions

L Polaris Premium All Season Grease or grease conforming to NLG

No. 2, such as Conoco Superlube M or Mobilegrease Special

F Use Polaris Premium U-Joint Lube every 500 miles, before long

periods of storage, or after pressure washing or submerging

∆ When suspension action becomes stiff, or after washing

Item Lube Method Frequency

2-Cycle Engine

4-Cycle Engine

Brakes DOT 3 fluid only Maintain level between fill

Drive chain(s) O-ring chain lube

(1) Transmission

(2) Front Gearcase

(3) Visco Drive

(4) Front Prop Shaft U-joints

(5) Front Prop Shaft Yoke

Polaris Injection Oil

Polaris Premium 4 Synthetic 0W40

or SAE 80/90

Polaris Premium Synthetic gear case lube

FGrease Grease fittings. Every 3 months or

FGrease Grease fittings (3 pumps

Fill oil tank. See page 45. As needed,

Add to proper level on dipstick.

lines. See page 39.

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

See Page 91. Check every 6

See Page 95. Change annually or

maximum)

when refueling Check level daily.

As required; change every two years or 200 hours

As required

months/1000 miles. Change annually or at 100 hours

at 100 hours

Change annually or at 100 hours

50 hours Every 3 months or

50 hours

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

(1)

(2)

(3)

(4)

(2)

(5)

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Item Lube Method Frequency

(6) Demand 4 Hubs - All Wheel Drive ATVs

(7) Front Drive Axle (U Joint) (AWD Models)

(8) Ball Joint

(9) Counter Balance Housing (400)

(10) Rear Axle Bearing

(11) Swing Arm Bushings

(12) Upper Control Arms

(13) Lower Control Arms

(14) Rear Wheel Hub Bearing Carrier

(15) Rear AntiRoll Bar

Premium Hub Lube

FGrease Locate grease fitting and grease with

Grease

Polaris Premium Synthetic 4-cycle or SAE 10/30

Grease

"L∆

Grease

"L∆

Grease

"L∆

Grease

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

grease gun.

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

Check level on dipstick and add oil as necessary. Change annually.

Locate fittings and grease Every 3

Locate fittings on swing arm and grease with grease gun.

Locate fittings and grease Semi-annually

Locate fitting and grease Semi-annually

Annually or at 100 hrs.

Every 3 months or 50 hours

Check monthly and change annually

months or 50 hours

Monthly or at 20 hours

" More often under severe use, such as wet or dusty conditions

L PolarisPremium AllSeason Grease orgrease conforming to NLGINo. 2,such

as Conoco Superlube M or Mobilegrease Special

F Use Polaris Premium U-Joint Lube every 500 miles, before long

periods of storage, or after pressure washing or submerging.

∆ When suspension action becomes stiff, or after washing

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

(6)

(7)

(8)

(10)

(6) 4 O’clock position

(11)

(9)

(12)

(14)

(15)

(13)

MAINTENANCE AND LUBRICATION

Periodic Maintenance Record

Use the following chart to record periodic maintenance.

Maintenance

Interval

Performed

10 hrs. 20 hrs. 50 hrs.

100 hrs.

Servicing

Date

Servicing

Dealer

or Person

Remarks

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Polaris 2-Cycle Lubricants

Polaris Premium 2-cycle lubricants are the most advanced formulation of oils, specifically designed for today’s 2-cycle engines. Our ongoing lab and field tests have resulted in a new generation of 2-cycle lubricants.

Polaris Premium 2-cycle lubricants provide additives for 2-cycle engines (lacking in today’s fuel). These necessary additives keep ring grooves cleaner for less ring sticking and improved overall engine cleanliness. With new generation lubricity technology, Polaris oils excel in meeting the lubrication demands of today’s high performance 2-cycle engines. These optimum oils are recommended for liquid cooled and air cooled 2-cycle engines.

Polaris Premium 2-cycle oils will readily mix with each other, but do not mix Polaris Premium 2-cycle oils with any other brand of oil, including our Nature Oil Biodegradable oil. Their incompatibility could result in engine damage.

See page 141 for the part numbers of Polaris-recommended products.

Premium Gold Synthetic 2-Cycle Oil

Your vehicle has been primed with Premium Gold Synthetic oil. This lubricant has been specially formulated for low smoke, low odor and high lubricity.

Premium 2-Cycle Oil

Polaris also has a TC-W3 premium oil available for use in all of our 2-cycle products. We highly recommend its use if Premium Gold Synthetic is not used.

CAUTION

Mixing brands or using a non-recommended oil may cause serious engine damage. We recommend the use of Polaris Premium 2-cycle oil or Premium Gold Synthetic 2-cycle oil for your 2-Cycle engine. Never substitute or mix oil brands.

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Premium 4 Synthetic Oil

Polaris Premium 4 All Season Synthetic engine oil has been specially formulated for use in Polaris 4-cycle engines. It’s a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection. NOTE: See page 141 for the part numbers of Polaris-recommended products.

Premium 4 possesses unsurpassed film strength over the widest possible t emperature range. It resists viscosity and frictional breakdown in ambient temperatures from -40° F. to 120° F. Its exceptional frictional properties result in more efficient operation, more power output and lower fuel consumption.

Although Polaris Premium 4 is the only oil recommended for use in this engine, use of any API certified “SH” oil is allowable as long as it’s 0W-40. Oil may need to be changed more frequently if Polaris Premium 4 is not used. Follow the manufacturer’s recommendations for ambient temperature operation.

CAUTION

Mixing brands or using a non-recommended oil may cause serious engine damage. We recommend the use of Polaris Premium 4 All Season synthetic oil or API certified “SH” oil, 0W-40. Never substitute or mix oil brands. Use only 0W-40.

Oil and Filter Change

4-Cycle Engines With External Oil Tank

The recommended oil change interval is 100 hours, 1000 miles, or every six months, whichever comes first.

Suggested break-in oil change is at 20 hours, 200 miles, or one month, whichever comes first. Severe use operation requires more frequent service. Severe use includes continuous duty in dusty or wet conditions and cold weather riding. NOTE: Severe use cold weather riding is all riding below 10° F., and riding between 10° F and 30°F when most trips are slow speed and less than 5 miles.

Be sure to change the oil filter whenever changing oil

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Oil and Filter Change

4-Cycle Engines With External Oil Tank

1. Position the vehicle on a level surface.

2. Clean the area around the drain plug, which is located on either the bottom of the oil tank or on the bottom of the engine.

3. Run the engine for two to three minutes until warm, then turn the engine off.

CAUTION

Contact with hot oil may result in serious burns. Do not allow hot oil to come into contact with skin.

4. Place a drain pan beneath the vehicle and remove the drain plug.

5. Allow the oil to drain completely.

6. Install a new sealing washer on the oil drain plug. NOTE: The sealing surfaces on the drain plug and on the oil tank should be clean and free of burrs, nicks or scratches.

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

8. Disconnect the lower oil delivery hose. R emove the fitting (C) from the oil tank. Clean the fitting screen. Reinstall the fitting screen, torquing to 14-17 ft. lbs. (19-23 Nm). Reattach oil line. Torque hose clamp (E)to25in.lbs.

9. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter counterclockwise to remove.

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

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Oil and Filter Change

4-Cycle Engines With External Oil Tank

11. Lubricate the gasket on the new filter with a film of new engine oil. Make sure the gasket is in good condition. Also make sure the gasket from the old filter is not still on the engine.

12. Install the new filter (1) and tighten by hand 1/2 to 3/4 turn after the gasket contacts the engine.

13. Approximately one cup of engine oil will remain in the crankcase sump. To drain, remove the drain plug on the l ower right side of the crankcase.

CAUTION

Loss of oil pump prime could result in engine damage. It’s extremely important to drain, refill and start the engine in an expedient manner. Do not allow the engine to sit without oil for extended periods.

14. Reinstall the drain plug. NOTE: The sealing surfaces on the drain plug and crankcase should be clean and free of burrs, nicks or scratches.

15. Remove the dipstick (2) and add the amount of oil indicated in your owner’s manual supplement. Reinstall the dipstick. NOTE: If the sump is not drained, add about 1 3/4 quarts initially.

16. Place the gear selector in neutral and set the parking brake.

17. Start the engine and let it idle for one to two minutes. Stop the engine and i nspect for leaks.

18. Re-check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick.

19. Dispose of used filter and oil properly.

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Oil and Filter Change

Magnum 330 2x4, Magnum 330 4x4, Trail Boss

1. Position the vehicle on a level surface.

2. Clean the area around the drain plug (1).

3. Run t he engine for two to three minutes until warm. Stop the engine.

CAUTION

Contact with hot oil may result in serious burns. Do not allow hot oil to come into contact with skin.

4. Place a drain pan beneath the engine crankcase and remove the drain plug.

5. Allow the oil to drain completely.

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

7. Reinstall the drain plug and torque to 14 ft. lbs. (19 Nm).

8. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter counterclockwise to remove.

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

10. Lubricate the gasket on the new filter with a film of engine oil. Check to make sure the gasket is in good condition.

11. Install the new filter and turn by hand until the filter gasket contacts the sealing surface, then turn and additional 1/2 turn.

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Oil and Filter Change

Magnum 330 2x4, Magnum 330 4x4, Trail Boss

12. Remove the dipstick and fill the sump with 2 quarts (1.9 l) of Polaris Premium 4 synthetic oil.

13. Place the gear selector in neutral and set the parking brake.

14. Start the engine and let it idle for one to two minutes. Stop the engine and inspect for leaks.

15. Recheck the oil level and add oil as necessary to bring the level to the upper mark on the dipstick.

16. Dispose of used filter and oil properly.

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Transmission Oil Check - Models with Fill Plug

Scrambler 500 4x4, Magnums: 500, 330 4x4, 330 2x4

The t ransmission lubricant level should be checked every six months or 1000 miles (1600 km), whichever comes first. Transmission oil should be changed annually.

1. Position the ATV on a level surface, remove the fill plug (1), and check the oil level. NOTE: The transmission fill plug is located on the right side of the machine, behind either the propshaft shield or footwell.

2. Use the gearcase oil fill chart and the following illustration to determine correct fluid levels. NOTE: When adding oil, use Polaris Premium Synthetic Gearcase Lubricant. See page 141 for the part numbers of Polaris-recommended products.

Gearcase Oil Fill Chart

Model

Scrambler 500 4x4 15/8″ 27 (800) Magnum 500 15/8″ 13.5 (400) Magnum 330 4x4 15/8″ 13.5 (400) Magnum 330 2x4 3/4″ 27 (800)

Magnum 4x4

Shown

Oil Level “A” Oil Fill Ounces (ml)

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Transmission Oil Change - Models with Fill Plug

Scrambler 500 4x4, Magnums: 500, 330 4x4, 330 2x4

1. If equipped, remove the propshaft shield from the right side of the vehicle to access the fill plug.

2. Remove the fill plug.

3. Remove the transmission drain plug located on the bottom left hand side and drain the oil. Catch and discard used oil properly.

4. Clean and reinstall the drain plug torque to 14 ft. lbs. (19 Nm).

5. Add the correct amount of Polaris Premium Synthetic Gearcase Lubricant. Refer the the gearcase oil fill chart on page 91 for proper oil levels.

6. Check for leaks.

7. Reinstall the propshaft shield if equipped.

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Transmission Oil Check - Models with Dipstick

On most 2x4 models, the transmission dipstick (1) is located on the right side of the machine. On the Sportsman, the dipstick is located near the rear brake disc.

The t ransmission lubricant level should be checked monthly or 1000 miles (1600 km), whichever comes first. Transmission oil should be changed annually.

1. Position the ATV on a level surface, remove the fill plug dipstick and wipe it clean.

2. Reinstall the dipstick completely, then remove it and check the level. Add the proper lubricant as required to bring level into the safe operating range. NOTE: When adding oil, use Polaris Premium Synthetic Gearcase Lubricant. See page 141 for t he part numbers of Polaris-recommended products.

Transmission Oil Change - 2x4 Models

1. Place a drain pan beneath the transmission oil drain plug area.

2. Loosen the jam nut (A).

3. Turn the adjuster bolt (B) in to allow the removal of the drain plug (C).

4. Remove the drain plug and wipe the magnetic end clean to remove accumulated metallic filings.

5. After the oil has drained completely, install a new sealing washer and reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm).

6. Turn the adjuster bolt (B) out until it touches the frame, and then turn an additional 1/2 turn.

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Transmission Oil Change - 2x4 Models

7. Tighten the jam nut securely while holding the adjuster bolt.

8. Add the proper l ubricant through the dipstick hole until the oil level is between the upper and lower limits. Do not overfill.

9. Check for leaks.

Transmission Oil Change - Sportsman

1. Remove the fill plug/dipstick.

2. Remove the transmission drain plug and drain the oil. Catch and discard used oil properly.

3. Clean and reinstall the drain plug.

4. Add 32 oz. (948 ml) of Polaris Premium Synthetic Gearcase Lubricant to t he full mark on the fill plug/dipstick. Maintain the oil level in the safe operation range (1). NOTE: See page 141 for the part numbers of Polaris-recommended products.

5. Reinstall the fill plug/dipstick and check for leaks.

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Front Gearcase Oil Check

The front gearcase oil level should be checked every six months or 1000 miles (1600 km), whichever comes first. The oil should be changed annually. Use Polaris Premium Synthetic Gearcase Lube (or GL5 80-90 weight gear lube). NOTE: See page 141 for the part numbers of Polaris-recommended products.

Type A and B - With the ATV on a level surface, remove the fill plug and check the oil level. The level should be maintained at the bottom of the fill plug threads.

Typ e C - The lubricant level in this type of gearcase cannot be checked. Periodically drain the oil and refill.

Front Gearcase Oil Chang e

1. Position the vehicle on a level surface and remove the fill plug (1).

2. Place a drain pan beneath the gearcase, remove the gearcase drain plug, and drain the oil.

3. Clean and reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm).

4. Add the recommended gear lube according to the following chart.

5. Reinstall the fill plug and check for leaks.

Gearcase

Type

A 4 oz. (120 ml) B 13.5 oz. (400 ml ) C 5 oz. (150 ml)

Capacity

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Rear Gearcase Oil Check

With the ATV on a level surface, remove the fill plug and view the oil level through the fill hole (1). Lubricant should be kept even with the center of the drillpoint (2), approximately 1 5/8″ below the t op of the fill hole. Use Polaris Premium Synthetic Gearcase Lube (or GL5 80-90 weight gear lube). NOTE: See page 141 for the part numbers of Polaris-recommended products. NOTE: Do not add lubricant to the bottom of the fill plug threads.

Rear Gearcase Oil Change

1. Remove the drain plug (3). Catchanddiscardusedoil properly.

2. Clean and reinstall the drain plug with a new sealing washer. Torque to 14 ft. lbs. (19 Nm).

3. Remove the fill plug and add 10 oz. (300 ml) of the recommended gear lube. Maintain the oil level even with the center of the drillpoint (approximately 1 5/8″ below the top of the fill hole).

4. Reinstall the fill plug. Torque to 14 ft. lbs. (19 Nm).

5. Check for leaks.

15/8″

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Counter Balance Oil Check - 400 2-Cycle Engines

The counter balance oil should be checked semi-annually and oil should be added or changed as needed. The oil should be changed annually and before off season storage. If the machine is used in wet conditions, check the oil more frequently. NOTE: If the oil has a milky appearance it should be changed as soon as possible.

Failure to properly maintain the counter balance lubrication can result in premature wear or possible failure of the counter balance components. Always use SAE 10W30 oil.

1. Remove the seat and remove the dipstick (1).

2. Read the oil level. If necessary, add SAE 10W30 oil with a transmission fluid funnel until the oil reaches the recommended level on the dipstick (2). NOTE: If overfilled, the excess oil will be expelled through the vent hose.

3. Reinstall the dipstick and reinstall the seat.

Counterbalance Oil Change - 400 2 -Cycle Engines

Drain Locations

A Counter Balance Drain B Crankcase Drain C Recoil Drain D Starter Pinion Drain

1. Remove the skid plate and remove the counter balance drain plug (A). Catchusedoilanddiscardof properly.

2. Clean and reinstall the drain plug.

3. Add 10W30 oil to the full mark on the dipstick. Capacity after draining is approximately 2.3 - 2.5 oz. (70-75 cc).

4. Reinstall the dipstick and check for leaks.

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Engine Oil Check

The oil tank is located either on the left side of the vehicle (external tank models)(1) or on the engine (2).

1. Position the machine on a level surface.

2. Start the engine and let it idle for 20-30 seconds. Stop the engine.

3. Remove the dipstick and wipe it dry with a clean cloth.

4. Screw the dipstick completely in. NOTE: The dipstick must be screwed completely in to keep the angle and depth of the stick consistent.

5. Remove the dipstick and read the oil level. Maintain the oil level in the normal (safe) operating range (3). Do not overfill.

ADD 8 OZ. NORMAL FULL

Polaris Magnum 500, Scrambler 500, Trail Blazer 400, Trail Blazer 250, Sportsman 600 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual