Polaris Offroad Vehicle User Manual

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WARNING

The engine exhaust from this

product contains chemicals known

to cause cancer, birth defects or

other reproductive harm.

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

FOREWORD

Congratulations and thank you from Polaris Industries Inc. for purchasing one of our all-terrain vehicles (ATV’s). Built with American engineering and manufacturing k now-how, it is designed to provide superior riding comfort, enjoyment and safety.

This manual is furnished to ensurethatthe operatorisaware of safe operating procedures. It also includes information about the general care and maintenance of you r ATV.

Carefully read the following pages. If you have any questions regarding this ATV contact a Polaris dealer for assistance. Remember, Polaris dealers have the knowledge and facilities to provide you with the best service possible.

PROTECT YOUR SPORT

Know all local, state/province riding laws;

Respect your vehicle;

Respect the environment; and

You will gain the respect of others.

We also advise you to strictly follow the recommended maintenance program as outlined. This preventive maintenance program is designed to ensure that all critical components on this ATV are thoroughly inspected at various intervals.

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

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

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

AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An

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

SEVERE INJURY OR DEATH can result if you do not follow these instructions:

• Read this manual and all labels carefully and follow the operating procedures

described.

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

ginnersshould receive trainingfroma c ertifiedinstructor. Contact an authorized PolarisATV dealer or call Polarisat 1-800-342-3764 to find outabout thetraining courses nearest you.

• Never allow anyone under 18 years of age to operate this ATV.

• Never permit a guest to operate this ATVunless the guest has read this manual

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

• Never operate an ATV on any paved surfaces, including sidewalks, driveways,

parking lots and streets.

• Never operatean ATV without wearing an approved helmet that fitsproperly. You

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

• Never consume alcohol or drugs before or while operating this ATV.

• Never operate at excessive speeds. Always travel at a speed which is proper

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

• Never attempt wheelies, jumps or other stunts.

• Always inspect your ATV each time you use it to make sure it is in safe operating

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

• Always keep both hands on the handlebars and both feet on the footrests of the

ATV during operation.

• Always go slowly and be extra careful when operating on unfamiliar terrain. Al-

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

• Never operate on excessively rough, slippery or loose terrain.

• Always follow proper procedures for turning as described in this manual. Prac-

tice turning at low speeds before attempting to turn at faster speeds. Do notturn at excessive speed.

• Always have the ATV checked by an authorized Polaris dealer if it has been in-

volved in an accident.

• Neveroperate the ATV on hills too steep for the ATV or for your abilities. Practice

on smaller hills before attempting larger hills.

• Always follow proper procedures for c limbing hills as described in this manual.

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

• Always follow proper procedures for going down hills and for braking on hills as

described in this manual. Check the terrain carefully before you start down any hill. Shift yourweight backward. Never go down a hill athigh speed. Avoidgoing down a hill at an angle which wouldcause the vehicle to lean sharplyto one side. Go straight down the hill where possible.

• Always followproper proceduresfor crossing the side of a hill as described in this

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

• Always use proper procedures if you stall or roll backwards when climbing a hill.

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

• Always check for obstacles before operating in a new area. Never attempt to

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

• Always be careful of skidding or sliding. On slippery surfaces, such as ice, go

slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.

• Never operate an ATVin fast flowingwater or in water deeper than that specified

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

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

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

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

proper tire pressure as described in this manual.

• Never modify an ATV through improper installation or use of accessories.

• Neverexceed the stated load capacity for an ATV. Cargo should be properlydis-

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

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

indicates a potential hazard which

WARNING

couldresult in seriousinjuryor death.

Additional Important Information...

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

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

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

NOTE:

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

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

Familiarize yourself with their function and affect on the ATV.

The Polaris Preferred

Registered Owners

(PRO) Family

Your Owners Program

As the owner of a new Polaris vehicle, you are entitled to a FREE two- year membership in the Polaris PRO Family---the Preferred Registered Owners Family. It’s an owners programfor Polarisowners likeyou, people who have chosen the finest recreational vehicle available, people who share an interestin Polarisand itsproducts.

Once your new vehicle’s warranty is registered, you will receive a PRO Family membership packet that will include:

A letter of welcome to the PRO Family A PRO Family card with your name and membership number A colorful sticker of the PRO logo A PRO merchandise brochure and order form.

As a PRO Family member, you’re entitled to opportunities such as:

A free subscription to PRO Spirit, the official magazine of the PRO Family The chance to buy insurance for you Polaris vehicle. The toll-free insurance

telephone number is: 1-800-473-0111

The chance to arrange travel through the Polaris Travel Center. The toll-free

travel telephone number is: 1-800-267-1915

The chance to apply to serve on PRO Consumer Councils that provide input

into the Polaris vehicles of the future

The chance to serve as a PRO Field Evaluator and provide feedback on your

new vehicle

The chance to take part in national PRO snowmobile, ATV or personal water-

craft rides

The chance to purchase exclusive PRO Family merchandise And more!

To order PRO merchandise, y ou’ll complete the order form you receive with your membershippacket, take the form to your Polaris dealer and pay for the merchandise. The merchandise will be shipped directly to your home from the PRO merchandise fulfillment center.

Watch for your PRO membership packet and the next issue of PRO Spirit magazine. This quarterly magazine will keep you informed about Polaris news and events, and special PRO merchandise, travel, and ride opportunities.

Enjoy your new Polaris vehicle,and welcome to thefamily--ThePolaris PRO Family.

CONTENTS

UNDERSTANDING WARNINGS 1-2..........................

SAFETY WARNING AND OPERATION DECALS 3-13...........

DAILY PRE-RIDE INSPECTION 14...........................

OPERATION WARNINGS 15-33..............................

VEHICLE IDENTIFICATION NUMBERS 34.....................

CONTROL AND PARTS FUNCTIONS 35-54...................

START ING THE ENGINE 55.................................

VEHICLE BREAK IN PERIOD 56-57..........................

RIDING GEAR 58...........................................

CARRYING LOADS 59......................................

CARGO WEIGHT DISTRIBUTION 60.........................

DAILY PRE-RIDE INSPECTION 61...........................

RIDING 62-72..............................................

BATTERY 73-74............................................

NOISE EMISSION CONTROL SYSTEM REGULATION 75.......

MAINTENANCE 76-131.....................................

TROUBLE SHOOTING 132.................................

PAINT CODES 133-134.....................................

ACCESSORIES 135-143....................................

WARRANTY 144-145.......................................

INDEX 146-147............................................

UNDERSTANDING WARNINGS

ATTENTION:

This is an ADULT VEHICLE ONLY; not a toy. Operation is prohibited for anyone under 18 years of age. READ AND UNDERSTAND WARNINGS AND OWNER’S MANUAL BEFORE OPERATION.

KNOW YOUR VEHICLE BEFORE YOU BEGIN RIDING!

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

SAFETY TRAINING

When you purchased this vehicleyour dealerpresented a hands-on safety training course covering all aspects of ATV safety. Inaddition, you were provided with certain printed material which instructs you on safe operating procedures. You should review this information on a regular basis. In the event you purchased a used Polaris ATV from a party other than a Polaris dealer, you can obtain this safety training at no charge from any authorized Polaris dealer. Failure to follow the warnings contained in this manual can result in SERIOUS IN-

JURY OR DEATH.

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

UNDERSTANDING WARNINGS

SAFETY ALERT

The following precautionary signal words are used throughout this manual to convey the following messages:

This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. Your safety is involved!

Indicates a potential hazard

WARNING

CAUTION

NOTE

The word “NOTE:” in this manual will alert you to key information or instructions.

which could result in serious injury or death.

Indicates a potential hazard which may result in minor personal injury or damage to the ATV.

WARNING

HAZARD Failure to heed WARNINGS.

WHAT CAN WARNINGS identify special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life.

HOW TO AVOID THE Read all WARNINGS in this manual carefully and for your safety be sure to follow their instructions.

HAPPEN

HAZARD

SAFETY WARNING AND OPERATION DECALS

NOTE:

Warning decals have been placed on the vehicle for your protection. Read and follow the instructions on each decal carefully. In the event any decal becomes illegible or comes off, contact your Polaris dealer for a replacement. Any safety decalneeding replacementwillbe providedby Polarisat no charge. The part number is printed on the decal.

SAFETY WARNING AND OPERATION DECALS

WARNING

READ AND UNDERSTAND WARNINGS AND OWNER’S MANUAL BEFORE OPERATION. SEVERE INJURY OR DEATH CAN RESULT FROM IGNORING WARNINGS OR IMPROPER USE.

TO REDUCE TIPOVER RISK, BE ESPECIALLY CAREFUL WHEN ENCOUNTERING OBSTACLES AND SLOPES, WHEN BRAKING ON HILLS OR DURING TURNS.

KEEP FEET ON FOOTRESTS AT ALL TIMES. HILL CLIMBING IS DANGEROUS, and should be attempted only by

experienced operators. Start on shallow slopes and practice procedures described in Owner’s Manual before trying steeper terrain. Some hills are too steep to safely stop or recover from an unsuccessful climbing attempt. Effectiveness of brakes is significantly reduced on hills.

Never operate this ATV on grades steeper than 25 degrees . If vehicle slides backwards down hill, apply hand brakes with gradual, even pressure to avoid flipover. Never open throttle suddenly as flipover may result.

REDUCE SPEED when operating this vehicle on rough or hilly terrain, or when carrying cargo on the racks.

REVERSE OPERATION CAN BE DANGEROUSeven atlow speeds. Steering control becomes difficult. When backing up, proceed slowly and apply hand brakes carefully; aggressive braking may result in flipover. Avoid backing downhill. Avoid turning at sharp angles in reverse.

USE OVERRIDE FOR REVERSE SPEED LIMITER WITH CAUTION; it allows full engine power and can result in excessive speeds. Never activate override button while throttle is open, as loss of control may result.

STOPPING DISTANCE MAY INCREASE with wet brakes or on wet surfaces. AUXILIARY FOOT BRAKE: The right foot auxiliary brake pedal operates the

rear brake only. When backing up or when operating on hills, avoid sudden use of the auxiliary brake; aggressive braking may result in flipover.

PARK BRAKE MAY RELAX WHEN USED FOR LONG PERIODS. When parking on grades, leave the gear shift in forward and don’t leave brake engaged for more than 5 minutes.

VEHICLE DESIGNED MAINLY FOR WARM WEATHERUSE. Throttle linkage and brakes may stick if operated in freezing weather, causing loss of control. Dirt, mud, water, or other contaminants can also affect operation of controls. Check both frequently.

ENGINE SHUT OFF SWITCH is available for use in event of throttle failure or other emergency when engine shut off is desired.

NEVER PERMIT A GUEST TO OPERATE THIS ATV unless the guest has read the Owner’s Manual and all labels, and has completed a certified training course.

25_

CAUTION: Do not shift transmission while vehicle is moving.

7075413

SAFETY WARNING AND OPERATION DECALS

ETC

This vehicle is equipped with a Polaris Electronic Throttle Control (ETC) to reduce the risk of a stuck or “frozen” throttle. Please refer to your Owner’s Manual for details.

7072724

WARNING

OVER-LOADING CAN CAUSE STEERING, TIPPING AND BRAKING PROBLEMS RESULTING IN LOSS OF CONTROL .

LOSS OF CONTROL CAN CAUSE SEVERE INJURY OR DEATH.

DO NOT OVERLOAD THE ATV. SEE YOUR OWNE R’S MA NUAL.

(Found on models with no racks)

7072786

WARNING

UNDER

Operating this ATV if you are under the age of 18 increases your chanc e of severe injury or death.

NEVER operate this ATV if you are under age 18.

7074827

WARNING

DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch.

(Found on models with racks)

7074954

SAFETY WARNING AND OPERATION DECALS

This decal is found only on models with dual racks.

WARNING

LOAD DISTRIBUTION WARNINGS

Correct loading of this vehicle is necessary to maintain proper stability and operating characteristics. Overloading or incorrect positioning of the load effects the vehicles turning, stopping distance and stability. Failureto follow loading requirements could cause severe injury or death. REDUCE SPEED AND ALLOW GREATER DISTANCE FOR BRAKING WHEN CARRYING CARGO.

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. Maximum cargo capacity is 270 lbs. on level terrain. When operating at maximum cargo capacity, the cargo weight distribution must be 90 lbs. on the front rack and 180 lbs. on the rear rack.

ALL LOADS MUST BE SECURED BEFORE MOVING VEHICLE. Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle.

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, theweight of the loads must be reduced to maintain stable operating conditions.

OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When handling offcentered loads which cannot be centered, securely fasten load and operate with extra caution.

EXTREME CAUTION MUST BE USED when operating with loads extending over the rack sides. Stability and maneuverability may be adversely affected, causing t he machine to overturn.

DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carryingloads on the front rack. SEE YOUR OWNER’S MANUAL.

7074110

SAFETY WARNING AND OPERATION DECALS

This decal is found on models with only rear racks.

WARNING

RACK LOAD WARNINGS

Correct loading of this vehicle is necessary to maintain proper stability and operating characteristics. Overloading or incorrect positioning of the load effects the vehicles turning, stopping distance and stability. Failure to follow loading requirements could cause severe injury or death. REDUCE SPEED AND ALLOW GREATER DISTANCE FOR BRAKING WHEN CARRYING CARGO.

MAXIMUM CARGO CAPACITY is 125 lbs. on level terrain. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions.

ALL LOADS MUST BE SECURED BEFORE MOVING VEHICLE. Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle.

LOADS MUST BE CARRIED AS LOW ON THE RACK AS POSSIBLE. Carrying loads high on the rack raises the center of gravity of the vehicle and creates a less stable operating condition. When cargo load is carried high on the rack, the weight of the load must be reduced to maintain stable operating conditions.

OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When handling off-centered loads which cannot be centered, securely fasten load and operate with extra caution.

EXTREME CAUTION MUST BE USED when operating with loads extending over the rack sides. Stability and maneuverability may be adversely affected, causing the machinetooverturn.

SEE YOUR OWNER’S MANUAL. 7074173

SAFETY WARNING AND OPERATION DECALS

ATTENTION

DOPERATION OF THIS VEHICLE WITHOUT

THE FILTER ELEMENT WILL SEVERELY DAMAGE THE ENGINE.

DCLEAN AIR FILTER OFTEN, MORE FRE-

QUENT CLEANING REQUIRED IN DUSTY CONDITIONS.

DLiutilisation de ce véhicule sous liélément

filtre endommage sévèrement le moteur.

DNettoyer souvent le filtre à air, surtout dans

des situations poussiereuses.

7072791

(Under Seat)

WARNING

BRAKE SHIELD COVERS MOVING PARTS. CONTACT WITH MOVING PARTS MAY RESULT

IN SEVERE INJURY. DO NOT REMOVE BRAKE SHIELD.

(On right side)

7075339

SAFETY WARNING AND OPERATION DECALS

DO NOT ATTEMPT ENGINE OR CLUTCH MODIFICATION. DOING SO CAN CAUSE IMBALANCE AND/OR EXCESSIVE ENGINE RPM.

EXCESSIVEENGINERPM CAN CAUSE PART FAILURE RESULTING IN POSSIBLE SEVERE INJURY OR DEATH.

DO NOT MODIFY ENGINE OR CLUTCH.

7077377

WARNING

BELT -- CLUTCH GUARD COVERS MOVING PARTS. CONTACT WITH MOVING PARTS MAY RESULT IN SEVERE

INJURY OR DEATH. DO NOT OPERATE VEHICLE WITH GUARD REMOVED.

NO STEP

7074946

SAFETY WARNING AND OPERATION DECALS

ATTENTION

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

Factory setting:

40° to 80° F. at 0-3000 feet. (+5° to 26° C. at 0-900 meters). 7073761

Chain Freeplay Is Important. Collapse Suspension To Adjust. DO NOT Overtension. See Owner’s Manual.

Torque E ccentric Bolts To 60 Ft. Lbs.

OVERRIDE

SWITCH

Reverse override and all wheel drive activation in reverse is controlled by the override switch. See your Owner’s Manual.

7076273

AWD Models 2WD Models

MANUFACTURED BY: POLARIS IND

DATE:

VIN:

THIS VEHICLE IS AN ALL TERR AIN VEH ICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS. THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE OF ITS MANUFACTUR E AS SHOWN ABOVE.

CE VÉHICULE EST UN VÉHICULE TOUT TERRAIN QUI NiEST PAS DESTINÉ À ÊTRE UTILISÉ SUR LES CHEMINS PUBLICS. CE VÉHICULE EST CONFORME À TOUTES LES NORMES DE SÉCURITÉ FÉDÉRALES PRESCRITES QUI SONT EN VIGUEUR À LA DATE DE SA FABRICATION INDIQUÉE CI-HAUT.

PRINTED IN U.S.A.

Le jeu libre de la chaine est important. Écrasez la suspension pour L’adjuster. Prenez soin de ne pas trop serrer la chaine. Voir le manuel d’opérateur.

Serrez les boulons de l’eccentrique à 60 livres/pieds de pression.

OVERRIDE

SWITCH

Reverse Speed is limited.

Reverse override is controlled by the override switch.

See your Owner’s Manual.

7076274

7073464

7074752

(Found on all models exc ept Sportsman 500)

TRAILER MAX. WEIGHT 850 LBS.

HITCH MAX. VERTICAL WEIGHT 30 LBS.

(Found on Sportsman 500)

TRAILER MAX WEIGHT: 1250 LBS. (568 KG) ON LEVEL GROUND 850 LBS. (368 KG) UP TO 15° GRADE

HITCH MAX. VERTICAL WEIGHT: 30 LBS. (14KG)

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.

7074935

POIDS MAX. DE REMORQUE 386 KG.

POIDS MAX. VERTICAL D’ATTACHE 14 KG.

7072533

7077542

CAUTION

VEHICLE LIGHTS WILL BURN OUT IF BATTERY IS DISCONNECTED DURING VEHICLE OPERATION.

PRECAUTION

Les phares et les ampoules du véhicul e sautent si la batterie est désaccouplée durant le fonctionnement du véhicule.

7072606

ATTENTION

LUBRICATE SWING ARM AND OUTPUT SHAFT BEARINGS MONTHLY ; MORE OFTEN IN WET OR VERY DUSTY CONDITIONS.

SEE YOUR OWNER’S MANUAL. 7074214

DAILY PRE-RIDE INSPECTION

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

WARNING

If a proper inspection is not performed serious injury or death can result. Always inspect your ATV before riding following the checklist carefully. Before riding your vehicle, inspect all operating controls and parts.

Item/Inspection Procedure

1. Tires - check condition and pressures

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

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

4. Throttle - check for free operation and closing

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

6. Engine stop switch - check for proper function

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

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

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

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

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

12. Operators helmet, goggles and clothing

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

OPERATION WARNINGS

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 operatethe ATV properly in differentsituationsand on different types of terrain.

HOW TO AVOID THE Beginning and inexperienced operators should complete the certified

trainingcourse offered by PolarisIndustries Inc. They should thenregularly 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 Use by children of ATVs that are not recommended for their age can

lead to severe injury or death of the child. Even though a child may be within the age group forwhich some ATVs

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

HOW TO AVOID THE No one under 18 should operate a Polaris ATV.

HAZARD

HAPPEN

HAZARD

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN Greatly reduces your ability to balance and control this ATV. Couldcause an accident,resultinginharm to youand/or your passenger. HOW TO AVOID THE Never carry a passenger. The long seat is to allow the operator to shift

position as needed during operation. It is not for carrying passengers.

HAPPEN

HAZARD

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN The ATV’s tires are designed for off-road use only; not for use on

pavement. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of control.

HOW TO AVOID THE Never operate the ATV on any paved surfaces, including sidewalks,

driveways, parking lots and streets.

HAPPEN

HAZARD

OPERATION WARNINGS

WARNING

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

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

and highways.

HAPPEN

HAZARD

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD Operatingthis ATV withoutwearing an approved helmet, eye protection

and protective clothing. WHAT CAN Operating without an approved helmet increases your chances of a se-

vere head injury or death in the event of an accident. Operating without eye protection can result in an accident and in-

creases your chances of a severe injury in the event of an accident. HOW TO AVOID THE Always wear an approved helmet which fits properly. You should also wear:

Deye protection (goggles or face shield); Dgloves; Dboots; Dlong-sleeved shirt or jacket; and Dlong pants.

HAPPEN

HAZARD

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN Could seriously affect your judgment. Could c ause y ou to react more slowly. Could affect your balance and perception. Could result in an accident. HOW TO AVOID THE Never consume alcohol or drugs before or while driving this ATV.

HAPPEN

HAZARD

WARNING

POTENTIAL Operating this ATV at excessive speeds. WHAT CAN Increasesyour chances of losing control of the ATV, which can result

in an accident. HOW TO AVOID THE Always travel at a speed which is proper for the terrain, visibility and

operating conditions; and your experience.

HAZARD

HAPPEN

HAZARD

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN Increases the chance of an accident, including an overturn. HOW TO AVOID THE Neverattemptstunts,such as wheeliesor jumps. Don’ttryto show off.

HAPPEN

HAZARD

OPERATION WARNINGS

WARNING

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

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

schedules described in the Owner’s Manual.

HAPPEN

HAZARD

WARNING

POTENTIAL Removing hands from handlebars or feet from footrests during op-

eration. WHAT CAN Removing even one hand or foot can reduce your ability to control

the ATVor could cause you to lose your balance and fall off the ATV. If you remove a foot from the footrest,your foot or leg may come into contactwiththe rearwheels, which could injure you or cause an accident.

HOW TO AVOID THE Alwayskeep both hands on the handlebarsand both feet on thefoot-

rests of your ATV during operation.

HAZARD

HAPPEN

HAZARD

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD Failureto use extra care when operatingthis ATVon unfamiliar terrain. WHAT CAN You can come upon hidden rocks, bumps, or holes, without enough

time to react. Could result in the ATV overturning or going out of control. HOW TO AVOID THE Go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the

ATV.

HAPPEN

HAZARD

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slip-

pery or loose terrain. WHAT CAN Could cause loss of traction or vehicle control, which could result in

an accident, including an overturn. HOW TO AVOID THE Do not operate on excessively rough, slippery or loose terrain until

you have learned and practiced the skills necessary to control the ATVonsuchterrain.

Always be especially cautious on these kinds of terrain.

HAPPEN

HAZARD

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD Turning improperly. WHAT CAN ATV could go out of control, causing a collision or overturn. HOW TO AVOID THE Alwaysfollow proper procedures forturningas described in the Own-

er’s Manual. See page 63 . Practice turning at low speeds before attempting to turn at faster

speeds. Do not turn at excessive speed.

HAPPEN

HAZARD

WARNING

POTENTIAL Operating on excessively steep hills. WHAT CAN The vehicle can overturn more easily on extremely steep hills than on

level surfaces or small hills. HOW TO AVOID THE Never operate the ATVon hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting large hills. Never operate ATV on hills steeper than 25_.

HAZARD

HAPPEN

HAZARD

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD Climbing hills improperly. WHAT CAN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE Always follow proper procedures for climbinghills as described in the

Owner’s Manual. See pages 65 through 68. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Neveropen the throttlesuddenly. The ATVcould 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

OPERATION WARNINGS

WARNING

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

the Owner’s Manual. See page 67. NOTE: A special technique is required when braking as you go downhill.

Always check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle which would cause the vehicle to

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

HAPPEN

HAZARD

OPERATION WARNINGS

WARNING

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

tered the turning technique as described in the Owner’s Manual on level ground. See page 68. Be very careful when turning on any hill.

Avoid crossing the side of a steep hill if possible. When crossing the side of a Alwaysfollow proper procedures as describedinthe Owner’sManual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.

HAPPEN

HAZARD

hill:

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN Could result in ATV overturning. HOW TO AVOID THE Maintain steady speed when climbing a hill. Ifyouloseallforward Keep weight uphill. Apply the brakes. Lock parking brake after you are stopped. If you begin rolling Keep weight uphill; never apply engine power. Never apply the rear brake while rolling backwards. Apply the single-lever brake gradually. When fully stopped, apply rear brake as well, and then lock parking brake. Dismount on uphill side, or to either side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in

the Owner’s Manual. See page 68.

HAPPEN

HAZARD

speed:

backwards:

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN Could cause loss of controlor a collision. Could cause the ATVto overturn. HOW TO AVOID THE Before operating in a new area, check for obstacles. Use extremecaution when riding over large obstacles, such as largerocks

or fallen trees. If you cannot avoid obstacles, always follow proper procedures as de-

scribed in the Owner’s Manual.

HAPPEN

HAZARD

WARNING

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

overturn. HOW TO AVOID THE On slippery surfaces, such as ice, go slowly and be very cautious in order

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

HAZARD

HAPPEN

HAZARD

WARNING

POTENTIAL Riding on frozen lakes and rivers. WHAT CAN Severe injury or death can result if the ATV and/or the operator break

through the ice. HOW TO AVOID THE Never ride your ATV on a frozen body of water before you are sure the ice

isthick enough and sound enough to support the machine and itsoperator, as well as the force that is created by a moving vehicle.

HAZARD

HAPPEN

HAZARD

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD Operating this 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. HOW TO AVOID THE Never operate this ATV in fast flowing water or in water deeper than

that specified in your Owner’s Manual. See page 69. Remember that wet brakes may have reduced stopping ability. Test

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

HAPPEN

HAZARD

WARNING

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

injury. HOW TO AVOID THE When you select reverse gear, make sure there are no obstacles or

people behind you. When it is safe to proceed, go slowly.

HAZARD

HAPPEN

HAZARD

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD Operatingthis ATV with improper tires, or with improperor uneven tire

pressure. WHAT CAN Use of impropertireson thisATV, or operation of this ATV withimprop-

er or uneven tire pressure, may cause loss of control, and increases the risk of an accident.

HOW TO AVOID THE Always use the size and type tires specified in the Owner’s Manual

Supplement for this vehicle. Always maintain proper tire pressure as described in the Owner’s

Manual Supplement.

HAPPEN

HAZARD

WARNING

POTENTIAL Operating this ATV with improper modifications. WHAT CAN Improperinstallationof accessories or modificationof this vehicle may

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

HOW TO AVOID THE Never modify this ATV through improper installation or use of acces-

sories. All parts and accessories added to this vehicle should be genuine Polaris Industries Inc. or equivalent components designed for use on this ATV; and should be installed and used according to instructions. If you have questions, consult an authorized Polaris ATV dealer.

HAZARD

HAPPEN

HAZARD

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN Could cause changes in vehicle handling which could lead to an ac-

cident. 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 greater

distance for braking. Alwaysfollow the instructionsin the Owner’s Manual for carryingcar-

go or pulling a trailer. See pages 59 and 60.

HAPPEN

HAZARD

WARNING

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

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 overturns and loss of control which could result in serious injury or death.

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

VEHICLE IDENTIFICATION NUMBERS

2Onrecoil housing

1 VIN on the lower left side of the frame tube

Important: Record these numbers from your ATV in the spaces provided.

1. Frame VIN

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

Remove the spare key and store in a safe place. Record your ignition key number here. It is a four digit number found stamped on the key. In the event the key is lost, replacement can be made by supplying your dealer with this number.

Ignition Key Number

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

Dealer Imprint

CONTROL AND PARTS FUNCTIONS

Engine Electrical Switches

1. Override Switch (Reverse Speed Limiter) - This vehicle is equipped with a reverse speed limiter system. Toobtain additional power while backing up, depress the override button. WARNING: Never activate the override button while throttle is open as loss of control may result, causing severe personal injury or death.

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

2. Main Switch - This switch must be turned clockwise to the “on” position to start the engine.

3. Emergency Engine Stop Switch - The engine will not start or run when the switch is in its “off” position. Its purpose is to provide the operator with a quick means of engine shutdown in case of stuck throttle or other emergency.

NOTE: Both the main switch and the emergency engine stop switch shut off all electrical power to the entire vehicle including lights.

4. Engine Start Button - Press to start the engine.

WARNING

Backing your ATV can be dangerous!

You could hit an obstacle or person behind you; or the vehicle could tip over rearward on a steep incline causing severe injury or death.

Alwaysback slowly avoiding excessivespeed and do not use the reverse speed override switch system unless additional power is required for vehicle movement.

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

CONTROL AND PARTS FUNCTIONS

Light Switches and Indicator Lights

Switches

Each Polaris ATV has a main switch. It is located on the right hand side of the machine and operated with a key.

The light switch is located on the left hand handlebar. In addition to turning the lights on and off, it also switches the lights from Hi to Lo on models equipped with Hi-Lo beams. NOTE: Will not light unless the main switch is on.

Indicator Lights

Each PolarisATVhas indicatorlights. The configuration of these lights differs with individualmodels and not every model is equipped with all the lights. The informationin your Owner’s Manual Supplementand in the followingbox will help you identify the lights on your machine and their function.

Transmission Neutral indicator - Green

Engine Hi Temp Warning Indicator

Transmission Reverse indicator - Yellow

Low Oil Warning Light (Red)

High Beam Indicator (Blue)

All Wheel Drive

Indicator - Red

(Refer to page

43 for location)

HI BEAM

If your machine has the following light configuration, use this diagram to determine indicator light location and function.

Neutral - Green

Hi Beam - Blue

Reverse - Yellow

Hi Temp Warning - Red (will

light only if engine overheats)

Low Oil Warning Light - Red

CONTROL AND PARTS FUNCTIONS

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

WARNING

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

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

indicates a potential hazard which

WARNING

couldresult in seriousinjuryor death.

CONTROL AND PARTS FUNCTIONS

Engine Throttle and Choke

Throttle Lever

Engine speed and vehicle movement are controlled by pressing the throttlelever. The throttle lever is spring loaded and engine speed returns to idle when the lever is released. This vehicle is equipped with a Polaris Electronic ThrottleControl(ETC)which is designed to reduce the risk of a frozen or stuck throttle. In the event the throttle should stick in an open position, engine RPM will diminish and power to the rear wheels will cease when the operator releases the throttle lever.

Choke Lever

Refer to the engine starting procedure on page 55 for correct choke and throttle settings during starting.

Choke

Throttle

WARNING

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

WARNING

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

Always contact y our dealer for service repairs whenever throttle problems arise.

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

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

CONTROL AND PARTS FUNCTIONS

Throttle Control/Brakes

Throttle Control Lever Stop

The throttle control lever incorporates an adjustable stop. This can be adjusted to limit the amount of throttle opening by loosening the screw (A)and sliding the stop to a desired setting. Then tighten screw.

Front and Rear Brakes

The brake fluid in the master cylinder, which is located on the left handlebar, should be checked before each ride. The fluid level can be seen through the plastic reservoir, and should be maintained between the indicated max and min marks on the reservoir. NOTE: When checking the fluid level, the ATV must be on level ground the the handlebars straight. If the fluid level is low add DOT 3 (PN 2870990) only.

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

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

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

Master Cylinder Reservoir

Bottom View

Max

Min

WARNING

Improperly operating the ATVwitha spongy brake lever can result in loss of braking. Loss of braking could cause an accident.

Never operate the ATV with a spongy feeling brake lever.

CONTROL AND PARTS FUNCTIONS

Parking Brake

Setting the Parking Brake

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

2. Rotate the park brake lock into the notcheson the master cylinderbody. Release the brake lever.

3. To release the parking brake lock, squeeze the brake lever. Itwillreturn to its released position.

Parking Brake Lock

WARNING

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

The parking brake may relax when left on for a long period of time. This could cause an accident.

Do not leave the vehicle on a hill depending on the parking brake for more than five minutes.

Always block the downhill side of the wheels if leaving the ATV on a hill or park the ATV in a side hill position.

Maximum

Minimum

Auxiliary Power Outlet

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

Outlets are located on the front headlight pod and/or rear taillight bracket. Do not use front and rear outlets simultaneously as increased battery drain will re-

sult. To determine if your vehicle is equipped with aux iliary power outlets, please check

your Owner’s Manual Supplement.

CONTROL AND PARTS FUNCTIONS

Auxiliary Mechanical Brake

Auxiliary Brake Pedal

Your Polaris ATV has an auxiliary mechanical brake provided as a safety feature. It is located on the inside of the right floor board and is operated by the right foot. It is intended as a backup to the hydraulic brake system, especiallyif the hydraulic system becomes inoperative.

WARNING: Use caution when applying the auxiliary mechanical brake. Do not aggressively apply the auxiliary brake when going forward or the rear wheels may skid and slide sideways causing loss of control. If the rear wheels slide, reduce brake pedal pressure to brake the rearwheels withoutskidding. Aggressively applying the rear brake when backing down a hill may cause rear tip over.

The auxiliary brake system is mechanical and requires periodic adjustment. Ifadjustment is necessary, please refer to page 106.

CONTROL AND PARTS FUNCTIONS

Transmission Gear Selector Operation

Shiftpatterns depend on the type ofvehicle you own. Please check your Owner’s Manual Supplement to define your machine’s shift pattern.

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

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

To change gears, stop the vehicle and with the engine idling, move the lever to the desired gear. Do not attempt to shift gears with engine speed above idle or while the vehicle is moving.

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

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

Shift Patterns

WARNING

1. Do not attempt to shiftthe transmission while the vehicle is moving or while operating on hilly terrain.

2. Always place the transmission in gear with the parking brake applied and turn the vehicle off whenever the vehicle is left unattended.

CONTROL AND PARTS FUNCTIONS

Demand 4 Drive

(Found on models with All Wheel Drive)

AWD Indicator Light

AWD

Button

Out “Off”

AWD

Button in

“On”

AWD Button

Exclusive Demand 4 Drive System (All Wheel Drive)

This Polaris AWD is equipped with a unique, Polaris exclusive, Demand 4 Drive (AWD) system which is activated by a switch on the right handlebar. When the switch is “off” the 4x4 is in 2 wheel drive at all times. When the switch is “on” the 4x4 is in Demand 4 Drive and the front wheels will automatically engage anytime the rear wheels lose traction. When the rear wheels regain traction, the front wheels will automatically disengage. NOTE: The override switch also allows activation of Demand 4 Drive (AWD) in reverse, if Demand 4 Drive switch is on.

The AWD button position and a red AWD light indicates when the vehicle is in Demand 4 Drive. There is no limit to the length of time the vehicle may remain in Demand4Drive.

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

CAUTION: Donot switch on Demand 4 Drive if the rear wheels are spinning. This may cause severe drive shaft and clutch damage. Engage the Demand 4 Drive switch before getting into conditions where front wheel drive may be needed. Ifthe rear wheels are spinning, release the throttle before turning the Demand 4 Drive switch on.

CONTROL AND PARTS FUNCTIONS

Disengaging Wheel Hubs

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

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

WARNING: If both hubs were engaged and only one released during opera-

tion, loss of control could result. If you experience hub engaging symptoms, use the above disengaging technique before proceeding. Failure to disengage front hubs as directed above could result in severe injury or death.

Ifthe hubs remain engaged after followingthese instructionsreturn the ATVto your dealer for service.

PVT System

WARNING

The PVT system rotates at high speeds, creating large amounts of force on clutch components. Extensive engineering and testing has been conducted to insure the safety of this product. However, as the owner you have the following responsibilities to make sure this system remains safe:

DDo not modify any component of the PVT system. Doing so may re-

duce its strength so that a failure may occur at high speeds. This system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components.

DRoutine maintenance is the responsibility of the owner. Always follow

recommended maintenance procedures. See your dealer!

DThis PVT system is intended for use on Polaris products only. DThe PVT housing must be securely in place during operation.

Failure to comply with this warning can result in severe injury or death.

CONTROL AND PARTS FUNCTIONS

Engine Cooling System

Coolant Level

The recovery bottle, located on the left side of the machine, must be maintained between the minimum and maximum levelsindicated on the recovery bottle.

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

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

NOTE: Some coolant level drop on new machines is normal as the system is purging itself of trapped air. Observe coolant levels and maintain as recommended by adding coolant tothe recovery bottle. Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. NOTE: Polaris Premium 60/40 is already premixed and readyto use. Do not dilute with water. NOTE: Always follow the manufacturer’s mixing recommendations for the freeze protection required in your area.

Recovery Bottle

Gen II

Gen III

Recovery Bottle

Gen IV

To access the recoverybottle on Gen IV machines it is necessary to remove theleft side panel as described on page 94.

CONTROL AND PARTS FUNCTIONS

Engine Cooling System

Radiator Coolant Level Inspection NOTE: This procedure is only re-

quired if the cooling system has been drained for maintenance and/or repair. However, if the recovery bottle has run dry, the level in the radiator should be inspected and coolant added if necessary.

WARNING Never remove the

pressure cap when the engine is warm or hot. Escaping steam can cause severe burns. The engine must be cool before removing the pressure cap.

To access the radiator pressure cap: Gen II - To access the pressure cap,

remove the access cover on the front of the ATV just below the oil cap. Using a flat, stubby screwdriver loosen the screw 1/4 turn and pull the cover forward and up to remove.

Gen III - To access the pressurecap, clean the area around the oil cap and remove the oil cap (2 cycle models). Remove front cover by placing your fingers under the front of the cover and pulling upward. Reinstall oil cap.

Gen IV - Remove the four screw securing front rack. Remove front cover by placing your fingers under the frontof the cover and pulling upward.

NOTE: Use of a non-standard pressure cap will not allow the recovery system to function properly. If the cap should need replacement contact your dealer for the correct replacement part.

Gen II

Pressure Cap

Gen III

Pressure Cap

Gen IV

Front Cover

Rack

CONTROL AND PARTS FUNCTIONS

Engine Cooling System

To insure that the coolant maintains its ability to protect the engine, it is recommended that thesystem be completely drained every twoyears and a freshmixture of antifreeze and water be added. Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. NOTE: Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. IMPORTANT: Al- ways follow the manufacturer’s mixing recommendations for the freeze protection required in your area.

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

CONTROL AND PARTS FUNCTIONS

Engine Fuel and Oil System

The fuel tank filler cap (1) is located directly behind the handlebar. Refer to your owner’sManual Supplement for tank capacity. Useeitherleaded or unleadedgasoline with a minimum pump octane number of 87 R+ M/2 octane.

On models with a two cycle engine, the engine oil injection tank filler cap (2) is located on the front of the machine. Refer to you Owner’s Manual Supplement to determine the type of engine your vehicle has. The tank capacity is 2 quarts (1.9 l). CAUTION: To avoid serious engine damage always top off the oil level when refueling.

CAUTION: On modelswith a two cycle engine,use onlyPolarisinjectionoil. Never substitute or mix oil brands. Serious engine damage and voiding of warranty can result.

The fuel tank supply decal located on the left side of the fuel tank cover displays the three fuel valve positions:

OFF: For vehicle storage and whenever transporting.

ON: For normal operation. RES: For reserve supply in the event of

main supply exhaustion. NOTE: There is about a 7 to 10 mile

(11.2 to 16 km) range on reserve gas. Always refill the gas tank as soon as possible after having used the reserve supply.

Alwaysreturn valve to “on” positionafter refueling machine.

OFF

RES

CONTROL AND PARTS FUNCTIONS

Engine Fuel Safety/Fuel/Filter

The Polaris ATV is equipped with a unique in-line fuel filter. This filter should be replaced by your dealer after every 100 hours of operation or

annually. Do not attempt to clean the fuel filter.

WARNING

Gasoline is highly flammable and explosive under certain conditions.

DAlways exercise extreme caution whenever handling gasoline. DAlways refuel with the engine stopped and outdoors or in a well venti-

lated area.

DDo not smoke or allow open flames or sparks in or near the area

where refueling is performed or where gasoline is stored.

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

with soap and water and change clothing.

DNever start the engine or let it run in an enclosed area. Gasoline

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

DShut off fuel valve 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.

CONTROL AND PARTS FUNCTIONS

4 Cycle Premium 4 Synthetic Lubricant

Polaris Premium 4 All Season Synthetic engine oil has been specially formulated foruse inPolaris4 cycle engines. It is a fully synthetic, high performance,multi-viscosity oil designed to provide the ultimate in lubrication performance and protection.

Premium4 possesses unsurpassed filmstrengthover the widest possible temperature 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.

AlthoughPolarisPremium4 is the only oil recommended for use in this engine, use of any API certified “SH” oil is allowable. Oil may need to be changed more frequently if Polaris Premium 4 is not used. You will also need to follow the manufacturers recommendations for ambient temperature operation.

Oil System

The oil tank is located on the left side of the vehicle. To check the oil:

1. Set machine on a level surface.

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

3. Stop the engine, remove dipstick and wipe dry with a clean cloth.

4. Screw in the dipstick completely, remove it and read the oil level. NOTE: The dipstick must be screwed in to keep the angle and depth of stick consistent.

5. Remove dipstickand check to see that the oil level is between the fulland add marks. Add oil as indicated by the level on the dipstick. Do not overfill.

CAUTION: Use only Polaris Premium 4 All Season synthetic oil (PN 2871271), or API certified“SH” oil. Neversubstitute or mix oil brands. Serious engine damage and voiding of warranty can result.

ADD 8 OZ. NORMAL FULL

Maintain Oil Level In Normal Range

Oil and Filter Change

The recommended oil change interval is 100 hours, 1000 miles, or every six months, whichever comes first. Suggestedbreak in oil change is at 20 hours, 500 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 (Polaris PN

3084963)

1. Place vehicle on a level surface.

2. Clean area around drain plug at the bottom of the oil tank.

3. Run engine for two to three minutes until warm. Shut engine off.

CONTROL AND PARTS FUNCTIONS

Oil and Filter Change (Cont.)

4. Place a drain pan beneath the oil tank and remove the drain plug. CAUTION: Oil may be hot. Do not allow hot oil to come into contact with skin as serious burns may result.

5. Allow oil to drain c ompletely.

6. Install a new sealing washer (PN 5850135) on oil drain plug. NOTE: The sealing surfaces on the drainplug and the oil tank should be clean and free of burrs, nicks or scratches.

7. Reinstall drain plug and torque to 14-17 ft. lbs. (1.93-2.35 kg/m)

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

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

10. Lubricate O-Ring on new filter with a film of new engine oil. Check to make sure the O-Ring is in good condition. Also make sure the O-ring from the old filter is not still on the engine.

11. Install new filter and tighten by hand 1/2 to 3/4 turn after gasket contact.

12. Approximately 1 cup of engine oil will remain in the crankcase. To drain, removedrain plug found on lower right side of crankcase. NOTE: The sealing surfaces on the drain plug and crankcase should be clean and free of burrs, nicks or scratches.

13. Reinstall drain plug.

14. Remove dipstick and add 2 quarts (1.9 l) of Polaris Premium 4 synthetic oil. Reinstall dipstick. NOTE: If sump is not drained, add about 1 3/4 quarts initially.

15. Place gear selector in neutral and set parking brake.

16. Start engine and letit idlefor one to two minutes. Stop engine and inspect for leaks.

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

18. Dispose of used filter and oil properly.

Fuel Filter and Oil Filter

Polaris 2 cycle ATVs are equipped with a unique in-line oil filter. All Polaris ATVs are equipped with a unique in-line fuel filter. These filters should be replaced by your dealer after every 100 hours of operation

or annually. Do not attempt to clean these filters.

Dipstick

4 Cycle

Filter

CONTROL AND PARTS FUNCTIONS

Polaris 2-Cycle Lubricants

Polaris has a family of premium oils available for use in all our products and highly recommends their use. The only oils recommended for Polaris 2-cycle ATVs are Polaris Premium 2-cycle oil or Premium Gold Synthetic 2-cycle oil.

CAUTION: Engine warranty coverage may become void if other brands are substituted.

Polaris Premium 2-cycle lubricants are the most advanced formulation of oils specifically designed for today’s 2-cycle engines. Months of lab and field tests have resulted in anew generation of 2-cycle lubricants. Polaris Premium 2-cycle lubricants provide additives for 2-cycle engines lacking in today’s fuel that keep ring grooves cleaner for less ring sticking and provide improvedoverall engine cleanliness. With new generation lubricity technology, they excel in meeting the lubrication demands of today’s high performance 2-cycle engines. These are optimum oils recommended for liquid cooled and air cooled 2-cycle engines. We believe these oils are the best available in the market today.

Premium Gold Synthetic 2-Cycle Oil

Your vehicle has been primed with PremiumGold Synthetic oil. This lubricant has been specially formulated for low smoke, low odor and high lubricity. We recommend continued use of this oil or Premium 2-cycle oil.

Premium 2-Cycle Oil

Polaris also has a TC-W3 premium oil available for use in all of our products. We highly recommend its use. The only oil recommended forthis ATVis Polarisbrand oil.

Polaris Premium 2-cycle oils will readily mix with each other, however do not mix PolarisPremium 2-cycle oils with any other oils as theymay not be compatibleand engine damage may occur.

CONTROL AND PARTS FUNCTIONS

Recoil Starter

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

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

1. Be certain your vehicle is on a level surface and the parking brake is set . See

page 40.

2. Take the machine out of gear.

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

gages.

4. Pull the rope abruptly to start the engine. CAUTION: Take care not to extend

the starter rope so far that it stops, causing damage to the recoil assembly.

CAUTION: Never start the engine with the battery disconnected. Damage to the electrical system and lamps will result.

CONTROL AND PARTS FUNCTIONS

Drainthe recoil housingafteroperatingtheATVin very wetconditions. Thisshould also be done before storing the ATV. The drain screw is located at the bottom of the recoil housing. Removethe screw with a 10mm wrench. Reinstall screwonce housing has been drained.

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

Water will enter the recoil housing if the starterhandle is disengaged from the rope guide when under water.

After travelling in wet areas the recoil housing and starter should always be drained completely by removing the recoil.

Do not open the crankcase drain unless the engine has ingested water. On 4-cycle engines, some engine oil will be lost if crankcase drain is opened.

On the Trail Blazer, the recoil handle must be behind the heat shield for it to seal properly. If it is not sealed properly, water may enterthe recoil housing and damage components.

Recoil Drain

Starter Pinion Drain

300 and 400 Engines

Crankcase Drain

Counter Balance Drain (400s Only)

4 Cycle Engines

Crankcase Drain

Recoil Drain (above front propshaft on shaft drive models)

STARTING THE ENGINE

Procedure for Starting a Cold Engine

1. Place the transmission in neutral and push the vehicle to a level surface.

2. Lock the parking brake.

3. Turn the fuel tank valve to ON.

4. Sit on the vehicle.

“FULL”

“HALF”

“OFF”

5. Move the choke lever to the FULL position.

6. Turn the ignition key to ON and the engine stop switch to RUN.

7. Press the starter button.

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

9. Press starter button for five seconds. If engine does not start, release starter button and wait five seconds; then press starter button for another five seconds. Repeat this procedure until engine starts.

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

Choke Lever Side View

After the Engine Starts

1. Ifthe engine slows or stops,use of the choke leverat its HALFpositionwillallow proper engine warm up.

2. Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly. Then move the choke to OFF.

CAUTION: Proper engine warm up is essential each time before driving to avoid engine damage.

WARNING

Carbon monoxide exhaust gas is poisonous! Always start the ATV outdoors. Never run the engine in an enclosed area.

VEHICLE BREAK-IN PERIOD

2 Cycle Engines

The break in period for your new Polaris ATV is defined as the time it takes to use the first tank of gasoline. No single action on your part is as importantas a proper break in period. Careful treatmentof a new engine will result in more efficientperformanceand longerlifefor the engine. Performthefollowingprocedurescarefully.

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

1. Mix 12.8 ounces of injection oil to four gallons of gasoline in a suitable gas can. Fill the fuel tank as outlined on pages 48 through 49.

2. Fill the oil tank with Polaris injection oil.

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

4. Vary the throttle positions. CAUTION: Do not operate at full throttle or high speeds for extendedperiods during the firstthree hours of use. Excessiveheat can build up and cause damage to close fitted engine parts.

5. Perform regular checks on fluid levels, controls and all importantareas on the vehicle as outlined earlier on the daily pre-ride inspection checklist found on page 14.

After the break in period the oil injection system provides the necessary engine lubricationwithout the need for pre-mixed fuel. CAUTION: To avoid serious engine damage always fill the oil tank when refueling the ATV.

After the first tank of pre-mixed fuel has been used please verify that the oil level in the oil tank has dropped, indicating that 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.

VEHICLE 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 timeittakes to use the first two tanks full of gasoline. No single action on your partis as important as a proper break in period. Careful treatmentof a new engine will result in more efficient performance and longer life for the engine. Perform the following procedures carefully.

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

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

2. Check oil reservoir level indicated on dipstick. Add oil if necessary.

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

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

5. Perform regular checks on fluid levels, controls and all importantareas on the vehicle as outlined earlier on the daily pre-ride inspection checklist found on page 14.

6. Pull only light loads.

7. Break in oil and filter. Change at 20 hours or 500 miles.

ADD 8 OZ. NORMAL FULL

Maintain Oil Level In Normal Range

RIDING GEAR

Safe Riding Gear

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

1. Helmet

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

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

2. Eye Protection

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

3. Gloves

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

4. Boots

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

5. Clothing

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

CARRYING LOADS

Your ATVhas been designed to carry a certain amount of load. CARGO WEIGHT should be evenly distributed (1/3 on the front and 2/3 on the rear) and mounted as low as possible. When operating over rough or hilly terrain,reducespeed and cargo to maintain stable driving conditions. Never exceed the following weights.

Model

Sportsman 500 470 lbs. (213 kg) 90 lbs. (41 kg) 180 lbs. (82 kg) Xplorer 300 470 lbs. (213 kg) 90 lbs. (41 kg) 180 lbs. (82 kg) Xplorer 400 470 lbs. (213 kg) 90 lbs. (41 kg) 180 lbs. (82 kg) Xplorer 500 470 lbs. (213 kg) 90 lbs. (41 kg) 180 lbs. (82 kg) Magnum 2x4 470 lbs. (213 kg) 90 lbs. (41 kg) 180 lbs. (82 kg) Magnum 4X4 470 lbs. (213 kg) 90 lbs. (41 kg) 180 lbs. (82 kg) Trail Boss 325 (148 kg) No Front Rack 125 (57 kg) Sport 400 L 200 (91 kg) No Front Rack No Rear Rack Trail Blazer 200 (91 kg) No Front Rack No Rear Rack Scrambler 400 200 (91 kg) No Front Rack No Rear Rack Scrambler 500 200 (91 kg) No Front Rack No Rear Rack

Maximum trailer weight - 850 lbs.(386 kg); maximum vertical hitch weight - 30 lbs.(14 kg). Sportsman 500 may tow up to 1250 (568 kg) on level ground only.

Maximumgrade while trailertowing - 15°. Do not tow any trailer on a grade steeper than 15°.

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

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

Total Load Capac-

ity

(includes driver &

cargo)

Front Rack

Cargo Maximum

Rear Rack

Cargo Maximum

CARGO WEIGHT DISTRIBUTION

2/3 of Load on Rear Rack

1/3 of Load on Front Rack

WARNING

Correct loading of this vehicle is necessary to maintain proper stability and operating characteristics. Overloading or incorrectpositioning of the load affects the vehicle’s turning, stopping distance and stability. Failure to follow loading requirements could cause severe injury or death. REDUCE SPEED AND ALLOW GREATER DISTANCE FOR BRAKING WHEN CARRYING CARGO.

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

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

ALL LOADS MUST BE SECURED BEFORE MOVING VEHICLE. Unsecured loads can create unstable operating conditions, which could result in loss of control of the vehicle.

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. Whencargo loads are carried high on the racks, the weight of the loads must be reduced to maintainstable operating conditions.

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

EXTREME CAUTION MUST BE USED when operatingwith loads extending overthe rack sides. Stability and maneuverability may be adversely affected, causing the machine to overturn.

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

DO NOT TRAVELFASTERTHAN 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.

DAILY PRE-RIDE INSPECTION

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

WARNING

Item/Inspection Procedure

1. Tires - check condition and pressures

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

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

auxiliary brake)

4. Throttle - check for free operation and closing

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

and switches

6. Engine stop switch - check for proper function

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

axle nuts are secured by cotter pins

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

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

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

any area

11. Loose parts - visually inspect v ehicle for any damaged or loose nuts/

bolts or fasteners

12. Operators helmet, goggles and clothing

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

at the recovery bottle

RIDING

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

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

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

4. Release the parking brake.

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

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

WARNING

indicates a potential hazard which couldresult in seriousinjuryor death.

RIDING

Making Turns

Practice making turns at slow speeds.

Polaris ATVs are equipped with a solid rear axle which drives both rear wheels equallyat all times. This means that the wheel on the outsideof the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly. To turn, steer in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. This technique alters the balance of traction between the rear wheels a llowing the turn to be made smoothly. The same leaning technique should be used for turning in reverse. WARNING: Avoid turning at sharp angles in reverse as tipover and serious injury may result.

indicates a potential hazard which

WARNING

couldresult in seriousinjuryor death.

RIDING

Riding On Slippery Surfaces

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

1. Slow down when entering slippery areas.

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

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

4. Driving with Demand 4 Drive (All Wheel Drive) engaged can assist in controlling the vehicle in slippery areas. CAUTION: Never engage Demand Drive while wheels are spinning as severe damage to drive train may occur.

WARNING

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

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

DNever apply brakes during a skid. Complete loss of ATV control can

result.

DDo not operate on excessively slippery surfaces if possible to avoid. DAlways reduce speed and use additional caution.

RIDING

Traveling Uphill

25_ Maximum

Whenever traveling uphill always travel straight uphill and:

1. Avoid steep hills.

2. Keep both feet on the footrests.

3. Transfer your weight forward.

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

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

WARNING

Braking and handling are greatly affected whenever operating in hilly terrain.

Loss of vehicle control or overturning of the ATV could occur.

DAvoid operating on steep hills (25_ maximum). DUse extreme care when operating your ATV in hilly terrain.

indicates a potential hazard which

WARNING

couldresult in seriousinjuryor death.

RIDING

Sidehilling

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

1. Slow down.

2. Lean into the hill transferring your upper body weighttoward thehill whilekeeping your feet on the footrests.

3. Steer slightly into the hill to maintain v ehicle directions.

If vehicle begins to tip,quickly turn the frontwheel downhill, if possible, ordismount on the uphill side immediately!

WARNING

Improperly crossing hills or turning on hills can be dangerous! Loss of vehicle control or overturning of the ATV could occur.

DAvoid crossing the s ide of a steep hill if possible. DUse extreme care when operating your ATV in hilly terrain.

RIDING

Traveling Downhill

Whenever descending a hill, always:

1. Drive directly downhill.

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

3. Slow down.

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

of normal service brakes occurs.

WARNING

Loss of vehicle control due to excessive speed can occur. Loss of control may result in serious injury or death.

RIDING

Turning Around On A Hill

8’

Uphill

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

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

2. Leave transmission in forward and shut off engine.

3. Dismount on left or uphill side of ATV.

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

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

6. Lock the parkingbrake and remountATVfromthe uphillside, maintaining body weight uphill.

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

WARNING

Avoid climbing steep hills. Loss of vehicle control or overturning of the ATV could occur. DUse extreme care when operating your ATV in hilly terrain.

RIDING

Crossing Streams

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

1. Determine water depths and current.

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

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

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

CAUTION: Should your ATV become immersed, it will be necessary to take it to your dealer as soon as possible. Do not start the engine! Immersion of the ATV can cause major damage if not correctly repaired.

WARNING

Never try to cross any deep or fast flowing streams. The large tires can cause the ATV to float resulting in loss of control. DDetermine stream depth and speed before crossing.

RIDING

Trail Obstacles

Keep Alert!

Look ahead and learn to read the trail as you ride. Stay on the right side of the trail, ifpossible,and be constantly alertfor hazardssuch as logs, rocksand low hanging branches.

WARNING

Hidden or unseen hazards on the trail can be dangerous. Personal injury or the vehicle overturningcan occur from unseen obstacles. DKeep alert and constantly look for obstacles on the trail.

indicates a potential hazard which

WARNING

couldresult in seriousinjuryor death.

RIDING

Backing Up

1. Whenever backing up, 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.

6. Neveractivateoverridebutton while throttleis open. Loss of controlmay result.

NOTE: This vehicle is equipped with a reverse speed limiter. The overridebutton should be used with caution as rearward vehicle speed is greatly increased. Do not operate at wide open throttle. Only open the throttle enough to maintain a desired speed. Opening the throttle more than required may cause excessive fuel to build in the exhaust, resulting in engine popping and/or engine damage.

WARNING

Backing your ATV can be dangerous! You could hit an obstacle or person behind you; or the ATV could tip over rearward on a steep incline.

DAlways back slowly, avoiding excessive speed; and do not use the

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

DAvoid backing on steep inclines.

ParkingonanIncline

RIDING

Whenever the Vehicle is Parked

1. Turn the engine off.

2. Place the transmission in gear.

3. Set the parking brake.

4. Avoidparkingon an incline. If itis necessary to park on an incline,always block the rear wheels on the down hill side as shown above.

5. Shut off fuel supply.

indicates a potential hazard which

WARNING

couldresult in seriousinjuryor death.

BATTERY

Battery

CAUTION

Whenever removing the battery, disconnect the negative (black) cable first. When reinstalling the battery, connect the negative (black) cable last.

Replenishing the Battery Fluid

A poorly maintained battery willdeteriorate rapidly. Check the battery fluid level often. The fluid level should be kept between the upper and lower level marks.

To refill use only distilled water . Tap

water contains minerals which are harmful to a battery.

Battery Connections

Battery terminals and connections should be kept free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with

a solution of one tablespoon baking soda and one cup water. Rinse well with tap waterand dryoffwith clean rags. Coatthe terminalswithdielectricgrease orpetroleum jelly.

Maintain between upper and lower level marks

Do not allow cleaning solution or tap water to enter the battery. It will shorten

the life of the battery.

Vehicle lamps will burn out if battery is disconnected during vehicle opera-

tion. Also, the reverse speed limiter can be damaged.

WARNING

Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote:

External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia,

beaten egg, or vegetable oil. Call physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away.

Ventilate when charging or using in an enclosed space. Always shield eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN.

BATTERY

Battery Removal

1. Disconnect hold down straps holding the electrical box and battery in position and remove battery cover.

2. Remove the battery vent tube from the battery.

3. Disconnect the black (negative) battery cable first.

4. Disconnect the red (positive) battery cable next.

5. Lift the battery out of the ATV, being careful not to tip it sideways and spill any electrolyte.

CAUTION: If electrolyte spills, immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the ATV.

Battery Installation

WARNING: To avoid the possibility of explosion, always connect battery cables

in the order specified. Red (positive) cable first; black (negative) cable last.

1. Set the battery in its holder.

2. Install the battery vent tube. It must be free from obstructions and securely installed. If not, battery gases could accumulate and cause an explosion. The tube should be routed away from the frame and body to prevent corrosion. Avoid skin contact with electrolyte, severe burns could result.

3. First connect and tighten the red (positive) cable.

4. Second connect and tighten the black (negative) cable.

5. Reinstall battery cover and attach the hold down strap.

6. Verify that cables are properly routed.

NOTE:

DWhen your ATV is placed in storage for three months or more, the battery

should be removed, charged to proper level, and stored in a cool dry place.

DBefore reusing, take the battery to your dealer for testing and recharging. DPower plug leads may need to be bent down s o that the battery cover may be

installed.

NOISE EMISSION CONTROL SYSTEM REGULATION

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

maintenance, repair, or replacement of any device or element of design incorporatedintoany new vehiclefor the purposeof noise controlprior to itssale ordelivery to the ultimate purchaser or while it is in use or

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

“AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW.”

1. Removal or alteration or the puncturingof 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. Replacementof any vehicle parts with parts notin compliance with federalregulations.

4. Lack of proper maintenance.

CAUTION: Remember,exhaust systemcomponents are very hot during and after use of ATV.

DDo not touch exhaust system components. Serious burns can result. DBe especially careful when traveling through tall grass. The potential for fire

exists.

USFS Approved Spark Arrestor

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

MAINTENANCE

Spark Arrestor

The exhaust pipe must be periodically purged of accumulated carbon as follows:

1. Remove the clean out plugs located on the bottom of the muffler as shown above.

2. Place the transmission in neutral and start the engine. Purge accumulated carbon from the system by momentarily revving the engine several times.

3. If some carbon is expelled, cover the exhaust outlet and rap on the pipe around the clean out plugs while revving the engine several more times.

4. If particles are still suspectedtobeinthemuffler, back the machine onto an inclineso the rear of themachine is one foot higher than the front. Set the parking brake and block the wheels. Make sure the machine is in neutral and repeat steps 2 and 3. WARN- ING: SEE BELOW.

5. If particles are still suspectedtobeinthemuffler, drive the machine onto the incline so the front of the machine is one foot higher than the rear. Set the parking brake and block the wheels. Make sure the machine is in neutral and repeat steps 2 and 3. WARN- ING: SEE BELOW.

6. Repeat steps 2 through 5 until no more particles are expelledwhen theengine is revved.

7. Stop the engine and allow the arrestor to cool.

8. Reinstallthe arrestor plugs.

Clean Out Plugs

Clean Out Plug

Clean Out Plugs

Clean Out Plug

Clean Out Plugs

MAINTENANCE

Spark Arrestor (Cont.)

WARNING

DDo not perform this operation immediately after the engine has been run

because the exhaust system becomes very hot.

DBecause of the increased fire hazard, make sure that there are no com-

bustible materials in the area when purging the spark arrestor.

DWear eye protection. DDo not stand behind or in front of the vehicle while purging the carbon

from the spark arrestor.

DNever run the engine in an enclosed area. The exhaust contains poi-

sonous carbon monoxide gas.

DDo not go under the machine while it is inclined. Failure to heed these warnings could result in serious personal injury or death.

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

MAINTENANCE

Tool Kits

To help you perform routine maintenance, a tool kit is provided in the storage compartment under the seat. Items included in the kits are:

2 cycle engines

Dflat screwdriver Dspark plug wrench with Phillips head screwdriver Dwrench Dtire pressure gauge Dspanner wrench for adjusting rear shock spring preload (selected models)

4 cycle engines

Dscrewdriver Dopen end wrench (8-10 mm) Dopen end wrench (12-14 mm) Dbox end wrench Dtire pressure gauge Dspark plug wrench and handle Dspanner wrench for adjusting rear shock spring preload (selected models)

NOTE: Other tools are also necessary to perform maintenance work. They are called out later in this manual.

Power Pig Tail

Some models are equipped with an auxiliary power outlet. Refer to your Owner’s Manual Supplementto determine if your machine has one.

A power pig tail is included in the tool kit . This pig tail will allow you to plug power accessories into the vehicle. Attach the pig tail to the power accessory and then plug into the rear power outlet of the vehicle.

CAUTION: Be sure to wrap bare wires with electrical tape and follow correct wire splicing procedures to avoid s horts in the wiring system.

Additional pig tails may be purchased under Polaris PN

2460442.

Power Outlet

Pigtail

MAINTENANCE

Periodic Maintenance Schedule

Carefulperiodicmaintenancewillhelp keepyour vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication intervals of important components are explained in the following chart

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

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

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

J CAUTION: Due to the nature of these adjustments, it is recommended that service be performed by an authorized Polaris dealer. Do not attempt to perform this work unless you are familiar with mechanical repair.

" More often under severe use, such as dirty or wet conditions L Emission Control System Service (California - 4-Cycle)

Item Hours or

Engine Oil - Level/Change

(4-Cycle)

Oil Filter(4-Cycle) 100 hrs/1000

Injector Oil Level (2-Cycle) Daily Daily Check when refueling

J Injector Oil Filter (2-Cycle) 100 hrs Annually Replace

Engine Counterbalance (400 Engines)

Oil Pump Cable (2-Cycle) 50 hrs 6 months Inspect, adjust, lubricate, replace if re-

Engine breather filter

(4 cycle)

Engine breather hose

(4 cycle)

Engine Mounts 100 hrs 12 months Inspect

Engine Cylinder Head and Cylinder Base Fasteners

Air Filter - Pre-Cleaner Daily Daily Inspect-Clean

AirFilter-MainElement Weekly Weekly Inspect-Replace if necessary

" Air Box Sediment Tube Daily Daily Drain deposits whenever visible

Valve Clearance (4-Cycle) 100 hrs 12 months Inspect/Adjust

Spark Plug 100 hrs 12 months Inspect--replace if necessary

Ignition Timing 100 hrs 12 months Inspect and adjust as needed

Odometer

100 hrs/1000 miles

miles

20 hrs Monthly Check oil level; change annual ly

20 hrs Monthly Inspect-- replace annually and as need-

100 hrs 6 months Inspect

25 hrs 3 months Inspect (re-torque required at first ser-

Frequency Remarks

6 months Check Level Daily; Break in Service at

6 months Replace with oil change

1 month. Change oil more often in cold weather use.

quired

vice only)

MAINTENANCE

Periodic Maintenance Schedule (Cont.)

Item Hours or

Fuel System 100 hours 12 months Check for leaks at tank cap, l ines, fuel

J Fuel Filter 100 hrs 12 months Replace annual ly

Carburetor Float Bowl 50 hrs 6 months Drain bowl periodically and prior to stor-

Idle Speed As Required As Required Adjust

J Throttle Cable/ETC Switch 50 hrs 6 months Inspect-- adjust, lubricate, replace if nec-

Choke (Enricher) Cable 50 hrs 6 months Inspect-- adjust, lubricate, replace i f nec-

Coolant/Level Inspection Daily Daily Replace engine c oolant every two

Coolant strength/pressure test system

Radiator 100 hrs 12 months Inspect/c lean external surface

Cooling System hoses 100 hrs 12 months Inspect

Spark arrestor 100 hrs 12 months Clean out

Recoil housing As required As required Drain moisture out after ridi ng in water

" General Lubrication 50 hrs 3 months Lubricate all fittings, pivots, cables, etc.

" Front hubs/fluid check (AWD) 50 hrs 6 months Check monthly

" Front hubs/fluid change (AWD) 100 hrs 12 months

" Front Gearcase OIl (shaft drive) 100 hrs 12 months Check monthly and change annually

" Transmission Oil Level 25 hrs Monthly Inspect monthly; change annually

Shift linkage 50 hrs 6 months Inspect, lubricate, adjust

J Shift selector box 200 hrs 24 months Change lubricant every two years

J Drive belt 50 hrs 6 months Inspect-- adjust, replace if necessary

J Clutches (drive and driven) 100 hrs 12 months Inspect, clean

J Steering 50 hrs 6 months Inspect dai ly, lubricate

J Toe adjustment As required As required Periodic inspecti on, adjust when parts

" Rear Axle 50 hrs 6 months Inspect bearings

" Front Suspension 50 hrs 6 months Inspect-- lubricate, tighten fasteners

" Rear Suspension 50 hrs 6 months Inspect, tighten fasteners

J Front wheel bearings 300 hrs 36 months Replace

" Drive Chain(s) 50 hrs 6 months Inspect daily, adjust and lubricate if

Battery 20 hrs monthly Check Terminals/clean/chec k fluid level

Headlight Aim As required As required Adjust if necessary

Odometer

100 hrs 6 months Inspect strength seasonally; pressure

Frequency Remarks

valve, filter, pump and carburetor. Replace lines ev ery two years.

age

essary; pre-ride inspection item

essary

years

test system annually

are replaced

needed

MAINTENANCE

Periodic Maintenance Schedule (Cont.)

Item Hours or

Headlamp Inspection Daily Daily Check operation daily; apply Polaris di-

Tail lamp inspection Daily Daily Check operation daily; apply Polaris di-

Brake System Pre-ride Pre-ride Pre-ride inspecti on item

J Brake fluid 200 hrs 24 months Change every two years

J Brake pad wear 10 hrs/100

Auxiliary As required As required Inspec t deflection daily; adjust

Tire s Pre-ride Pre-ride Inspect daily, pre-ride inspection item

Wheels Pre-ride Pre-ride Pre-ride inspection item

Frame nuts , bolts, fasteners Pre-ride Pre-ride Pre-ride inspection item

Odometer

miles

" More often under severe use, such as dirty or wet conditions L Emission Control System Service (California - 4-Cycle)

Frequency Remarks

electric grease to connector when replaced

electric grease to socket when replaced

Monthly Inspect periodically

MAINTENANCE

Lubrication Recommendations

Item Lube Rec. Method Frequency*

1. Engine Oil (2-Cycle)

2.Engine OIl (4-Cycle)

3. Brake Fluid DOT 3 Only Maintain level between fill lines.

4. Transmission Oil

5. Front Gear-

case Oil

6. Rear Half-

shafts

7. Front Prop

Shaft U-joints

8. Front Prop-

shaft Yoke

9. Speedometer Cable

10. Drive

Chain(s)

11.Demand 4 Hubs - All Wheel Drive ATVs

12. Front Drive Axle (U Joint) (AWD Mod els)

13. Ball Joint Grease** Locate fitting on back side of

Polaris Injection Oil

Polaris Premium 4 Synthetic 0W40

Polaris Premium Synthetic chain case lube

GL5 80-90 Weight Gear Lube

Grease+ Locate Fittings and Grease Every 3 months

Grease+ Locate fittings and grease -- 3

Polaris Cable Lube

O-Ring chain lube or SAE 80/90

Premium Hub Lube

Grease+ Locate grease fitting and grease

Fill oil tank. See page 48. As needed,

Add to proper level on dipstick. See page 50.

See page 39.

Add to FULL level on dipstick. See page 115.

Fill to bottom thread of filler hole. Make certain machine is on level surface.

pumps maximum Disconnect cable on back of

speedometer and lubricate inner cable.

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

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

with grease gun.

struts and grease with grease gun.

when refueling Check level dai-

ly.

As required; change every two years or 200 hours

Change annually or at 100 hours

Change annually

or 50 hours

or 50 hours Every 3 months

or 50 hours 3 months or 50

hours

As required

Annually or at 100 hrs

Every 3 months or 50 hours

MAINTENANCE

Lubrication Recommendations

14. Front A Arm Pivot Shaft

15. Counter Bal-

ance Housing (400)

16. Output Shaft

Support Bearing

17. Steering Post Bushings

18. Rear Axle Bearing

19. Swing Arm Bushings

20. Chain Ad-

justers (Center and Front Eccentrics)

21. Upper Control

Arms

22. Lower Control

Arms

23. Rear Wheel

Hub Bearing Carrier

24. Rear Anti-Roll

Bar

25. Tie Rod Ends Grease** Remove bolt above inner tie rod boot.

* More often under severe use, such as wet or dusty conditions. **Polaris Premium all Season Grease or grease conforming to NLGI No. 2, such as Conoco Superlube M or Mobilegrease Special. + Grease every 500 miles, or after submerging in water or before long periods of storage or after pressure washing. Always use Polaris Premium U-Joint Lube for maximum service of these driveline components (PN 2871515 3 oz.)(PN 2871551 14 oz.). ∆ When suspension action becomes stiff or after washing. NOTE: Hours are based on 10 mph average.

Grease**∆ Locate fitting on pivot shaft and

grease with grease gun.

SAE 10/30 Check level on dipstick and add oil as

necessary. Change annually. To change oil see page 117.

Grease ** Locate fitting on bearing and grease

with a grease gun.

Grease** Locate fittings on steering post and

grease with grease gun.

Grease** Locate fittings and grease Every 3

Grease** Locate fittings on swing arm and

grease with grease gun.

Grease** Locate fitting on center eccentric and

grease. Locate fitting on front eccentric (side opposite chain) and grease.

Grease**∆ Locate fittings and grease Semi-annually

Grease**∆ Locate fitting and grease Semi-annually

Grease Semi-annually

Lift boot. Clean away dirt and grease. Apply fresh grease by hand and reassemble. On models equipped with grease fitting, locate outer tie rod fitting and grease with grease gun.

Every 3 months or 50 hours

Check monthly and change annually

Monthly or at 20 hours

Every 3 months or 50 hours

months or 50 hours

Monthly or at 20 hours

Every 3 months or 50 hours

Lubrication Recommendations

5. Front Gear Case

4. Transmission

Full

Operating Range

7. Front Prop Shaft (U-Joint)

12. Axle Cardan Front Drive (AWD Models)

MAINTENANCE

Fill plug

8. Propshaft Yoke

6. Rear Halfshaft (U Joint)

9. Speedo

meter Cable

15. Counterbalance Dipstick

MAINTENANCE

Lubrication Recommendations

4WD

17. Steering Post Bushings

Lower

Upper

14. Front A-Arm Pivot Shaft

13. Ball Joint

17. Steering Post Bushings

25. Tie Rod End

11. Demand 4 Hubs

11. 4 O’clock position

Trail Boss

25. Tie Rod Ends

Upper

Lower

14. Front A-Arm Pivot Shaft

13. Ball Joint

Lubrication Recommendations

14. Front A-Arm Pivot Shaft

13. Ball Joint

MAINTENANCE

25. Tie Rod End

11. Demand 4 Hubs

11. 4 O’clock position

17. Steering Post

Bushings

Upper

Lower

14. Front A-Arm

Pivot Shaft

13. Ball Joint

MAINTENANCE

Lubrication Recommendations

16. Output shaft support bearing grease fitting

20. Center and Front Eccentrics

19. Swing Arm Bushings

18. Rear Axle Bearing

INDEPENDENT REAR SUSPENSION

21. Upper Control Arm

Forward

22. Lower Control Arm

24. Rear AntiRoll Bar

23. Rear Wheel HubBearingCarrier

MAINTENANCE

Periodic Maintenance Record

Use the following chart to record periodic maintenance work:

Maintenance

Interval

Performed

First 5 Hrs.

25 Hrs. 50 Hrs. 75 Hrs.

100 Hrs.

Servicing

Date

Servicing

Dealer

or Person

Remarks

MAINTENANCE

Steering

Handlebar Adjustment

Your ATV has handlebars which can be adjusted for your personal fit.

1. Locate handlebar bolts. On models with a headlight pod, it will be necessary to remove the upper headlight pod. On other models remove the handlebar cover.

2. Loosen the four bolts.

3. Adjust handlebar to desired height. Be sure handlebars do not hit gas tank or any other part of machine when turned fully to left or right.

4. Torque handlebar adjuster block bolts to 10 to 12 ft. lbs.

NOTE: Tighten bolts so there is an equal gap at the front and rear of the handlebar block. Improper gap will result in improper fit of upper pod.

WARNING

Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limitedsteering or loosening ofthe handlebars,resulting in loss of control and possible serious personal injury or death.

MAINTENANCE

2X4

4x4

The following items should be checked occasionally for tightness; or if they have been loosened for maintenance service.

Axle and Wheel Nut Torque Specifications

Model Item Specification

Front Spindle Nut(s) 40 Ft. Lbs.

2X4

4x4

Chain Drive

4x4

Shaft Drive

Front Wheel Hub Tightening

Front wheel bearing tightness and spindle nut retention are critical component operations. Service work must be performed by your authorized Polaris dealer.

Front Wheel Nuts 15 Ft. Lbs.

Rear Axle Nut(s) 80 Ft. Lbs.

Rear Wheel Nuts 50 Ft. Lbs.

Front Spindle Nut(s) Dealer Performed Service

Front Wheel Nuts 15 Ft. Lbs.

Rear Axle Nut(s) 80 Ft. Lbs.

Rear Wheel Nuts 50 Ft. Lbs.

Front Spindle Nut(s) Dealer Performed Service

Front Wheel Nuts 15 Ft. Lbs.

Rear Hub Retaining Nut(s) 100 Ft. Lbs.

Rear Wheel Nuts 15 Ft. Lbs.

Polaris Offroad Vehicle User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual