Polaris PTV 4x4 Series 10 Owner's Manual

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Page 1

Page 2

WARNING

The engine exhaust from this

product contains chemicals known

to cause cancer, birth defects or

other reproductive harm.

Page 3

Page 4

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

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

Page 5

WELCOME

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

Polaris Recreational and Utility Vehicles

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

Polaris Professional Series Workmobilest

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

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

For safe and enjoyable operation of your vehicle, be sure to follow t he instructions and recommendations in this owner’s manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory C ertified Master Service Dealer (MSD) Technician.

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

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

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

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IDENTIFICATION NUMBERS

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

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

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

31XX

Frame VIN:

Engine Serial Number:

Vehicle Model Number:

Key Number:

Page 7

TABLE OF CONTENTS

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

IDENTIFICATION NUMBERS 4........................

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

SAFETY 6..........................................

CONTROLS 38......................................

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

OPERATION 51.....................................

NOISE EMISSION CONTROL

SYSTEM REGULATION 69...........................

MAINTENANCE AND LUBRICATION 70................

SPECIFICATIONS 112................................

POLARIS RECOMMENDED PRODUCTS 115...........

TROUBLESHOOTING 116............................

W A RRANTY 120.....................................

INDEX 123..........................................

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

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SAFETY

Operator Safety

Age Restrictions

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

Know Your Vehicle

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

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

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

Safety Training

When you purchased your new PTV, your dealer offered a hands-on safety training course that covers all aspects of vehicle safety . You were also provided with printed materials that explain safe operating procedures. You should review this information on a regular basis.

If you purchased a used Polaris PTV from a party other than a Polaris dealer, you can request this free safety training from any authorized Polaris dealer.

WARNING

Failure to follow the warnings contained in this manual can result in severe injury or death.

A Polaris PTV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.

Read and understand your owner’s manual and all warnings before operating a Polaris PTV.

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SAFETY

Operator Safety

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

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

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

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

CAUTION

NOTE:

A note will alert you to important information or instructions.

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

CAUTION

WARNING

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SAFETY

Operator Safety

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

procedures described.

S Never operate the PTV without proper instruction. Take a training

course. Beginners should receive training from a certified instructor.

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

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

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

S Always avoid operating this vehicle on paved surfaces, including

sidewalks, driveways, parking lots, and streets.

S Never operate this vehicle on a public street, road or highway, in-

cluding a dirt or gravel road.

S Never operate this vehicle without wearing an approved helmet that

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

S Never consume alcohol or drugs before or while operating this ve-

hicle.

S Never operate at excessive speeds. Travel at speeds appropriate for

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

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

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

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

rests of the vehicle during operation.

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

miliar terrain. Be alert to changing terrain conditions.

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

WARNING

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

Page 11

SAFETY

Operator Safety

S Always follow proper turning procedures as described in this manu-

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

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

it’s been involved in an accident.

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

Practice on smaller hills before attempting larger hills.

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

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

S Always follow proper procedures for going downhill and for braking

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

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

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

S Always use proper procedures if the vehicle stalls or rolls backwards

while climbing a hill. To avoid stalling, maintain a steady speed when climbing a hill. Always dismount on the uphill side, or to either side if the vehicle is pointed straight uphill. Turn the vehicle around and remount following the procedure described in this manual.

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

attempt to operate over large obstacles, such as rocks or fallen trees.

S Always be alert to the potential for skidding or sliding. On slippery

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

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

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

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SAFETY

Operator Safety

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

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

S Always check for obstacles or people behind the vehicle before oper-

ating in reverse. When it’s safe to proceed in reverse, move slowly and avoid turning at sharp angles.

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

always maintain proper tire pressure.

S Never modify this vehicle through improper installation or use of

accessories.

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

be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for hauling cargo or towing. Allow a greater distance for braking.

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

prevent unauthorized use or accidental starting.

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

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SAFETY

Operator Safety

Equipment Modifications

We are concerned for the safety of our customers and for t he general public. Therefore, we strongly recommend that consumers do not install on a Polaris PTV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes. Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury.

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

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

WARNING

Make sure your PTV is in excellent operating condition at all times. We strongly recommend that the operator check all safety components before each ride.

Your Polaris PTV is designed to provide safe operation when used as directed. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power. The PTV may become aerodynamically unstable at speeds higher than those for which it is designed. Loss of control may occur at higher speeds. Modifications may also create a safety hazard and lead to bodily injury.

Do not make any modifications to your PTV.

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SAFETY

Operator Safety

POTENTIAL HAZARD Operating this vehicle without proper instruction. WHAT CAN

HAPPEN

The risk of an accident is greatly increased if the operator does not know how to operate the vehicle properly in different situations and on different types of terrain.

HOW TO AVOID THE

HAZARD

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

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

POTENTIAL

HAZARD Failure to follow the age recommendations for this vehicle. WHAT CAN

HAPPEN

Severe injury and/or death could occur if a person under the age of 16 operates a PTV.

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

HOW TO AVOID THE

HAZARD

No one under the age of 16 should operate a Polaris PTV.

WARNING

Page 15

SAFETY

Operator Safety

POTENTIAL HAZARD Carrying a passenger on this vehicle. WHAT CAN

HAPPEN

Carrying a passenger greatly reduces the operator’s ability to balance and control the vehicle, which could cause an accident and injury to the operator and/or passenger.

HOW TO AVOID THE

HAZARD

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

WARNING

Page 16

SAFETY

Operator Safety

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

paths, parking lots, and driveways. WHAT CAN

HAPPEN

PTV tires are designed for off-road use. Operating on paved surfaces may adversely affect the handling of the vehicle and could result in loss of control, accident and/or injury.

HOW TO AVOID THE

HAZARD

Avoid operating the vehicle on pavement. If it’s unavoidable, travel slowly and avoid sudden turns or stops.

WARNING

Page 17

SAFETY

Operator Safety

POTENTIAL HAZARD Operating this vehicle on public streets, roads or highways. WHAT CAN

HAPPEN The vehicle could collide with another vehicle. HOW TO AVOID THE

HAZARD

Never operate the vehicle on any public street, road or highway, including dirt and gravel roads.

WARNING

Page 18

SAFETY

Operator Safety

POTENTIAL HAZARD Operating this vehicle without wearing an approved helmet,

eye protection and protective clothing. WHAT CAN

HAPPEN

Operating this vehicle without an approved helmet increases the risk of a severe head injury or death in the event of an accident.

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

HOW TO AVOID THE

HAZARD Always wear an approved helmet that fits properly. Always wear eye protection (goggles or face shield), gloves,

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

WARNING

Page 19

SAFETY

Operator Safety

POTENTIAL HAZARD Operating the vehicle after consuming alcohol or drugs. WHAT CAN

HAPPEN

Consumption of alcohol and/or drugs could seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected.

Consuming alcohol and/or drugs before or while operating this vehicle could result in an accident causing severe injury or death.

HOW TO AVOID THE

HAZARD

Never consume alcohol or drugs before or while operating this vehicle.

POTENTIAL

HAZARD Operating the vehicle at excessive speeds. WHAT CAN

HAPPEN

Excessive speed increases the operator’s chance of losing control of the vehicle, which can result in an accident causing severe injury or death.

HOW TO AVOID THE

HAZARD

Always operate the vehicle at a speed that’s proper for the terrain, visibility and operating conditions, and your experience.

WARNING

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SAFETY

Operator Safety

POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN

HAPPEN

Attempting stunts increases the chance of an accident, including an overturn.

HOW TO AVOID THE

HAZARD

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

WARNING

Page 21

SAFETY

Operator Safety

POTENTIAL HAZARD Failure to inspect the vehicle before operating. Failure to properly maintain the vehicle. WHAT CAN

HAPPEN

Poor maintenance increases the possibility of an accident or equipment damage.

HOW TO AVOID THE

HAZARD

Always inspect your vehicle before each use to make sure it’s in safe operating condition.

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

POTENTIAL

HAZARD

Removing hands from the handlebars or feet from the footrests during operation.

WHAT CAN

HAPPEN

Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the vehicle.

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

HOW TO AVOID THE

HAZARD

Always keep both hands on the handlebars and both feet on the footrests of the vehicle during operation.

WARNING

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SAFETY

Operator Safety

POTENTIAL HAZARD Failure to use extra caution when operating the vehicle on

unfamiliar terrain. WHAT CAN

HAPPEN

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

HOW TO AVOID THE

HAZARD

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

WARNING

Page 23

SAFETY

Operator Safety

POTENTIAL HAZARD Failure to use extra caution when operating on excessively

rough, slippery or loose terrain. WHAT CAN

HAPPEN

Operating on excessively rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or overturn.

HOW TO AVOID THE

HAZARD

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

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

WARNING

Page 24

SAFETY

Operator Safety

POTENTIAL HAZARD Turning improperly. WHAT CAN

HAPPEN

Improper turns could cause loss of control and lead to a collision or overturn.

HOW TO AVOID THE

HAZARD

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

Practice turning at slow speeds before attempting to turn at faster speeds.

Never turn at excessive speed.

POTENTIAL

HAZARD Operating on excessively steep hills. WHAT CAN

HAPPEN The vehicle may overturn. HOW TO AVOID THE

HAZARD

Never operate on hills too steep for the vehicle or for your abilities. Never operate the vehicle on hills steeper than 25_.

Practice on smaller hills before attempting large hills.

WARNING

Page 25

SAFETY

Operator Safety

POTENTIAL HAZARD Climbing hills improperly. WHAT CAN

HAPPEN Improper hill climbing could cause loss of control or overturn. HOW TO AVOID THE

HAZARD

Always follow proper procedures for climbing hills as described in the owner’s manual.

Always check the terrain carefully before ascending any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly while traveling uphill. The

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

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

WARNING

Page 26

SAFETY

Operator Safety

POTENTIAL HAZARD Traveling downhill improperly. WHAT CAN

HAPPEN

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

HOW TO AVOID THE

HAZARD

Always follow proper procedures for traveling down hills as described in the owner’s manual. A special technique is required when braking while traveling downhill. See page 62.

Always check the terrain carefully before descending a hill. Shift your weight backward. Never travel down a hill at high speed. Avoid traveling down a hill at an angle, which would cause the

vehicle to lean sharply to one side. Travel straight down the hill when possible.

WARNING

Page 27

SAFETY

Operator Safety

POTENTIAL HAZARD Improperly crossing hills and turning on hills. WHAT CAN

HAPPEN

Improperly crossing or turning as hills could cause loss of control or overturn.

HOW TO AVOID THE

HAZARD

Never attempt to turn the vehicle around on any hill until you’ve mastered the turning technique (on level ground) as described in the owner’s manual. See page 63. Use extra caution when turning on any hill.

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

hill:

Always follow proper procedures as described in the owner’s manual.

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

WARNING

Page 28

SAFETY

Operator Safety

POTENTIAL HAZARD Stalling, rolling backwards or

improperly dismounting while climbing a hill.

WHAT CAN

HAPPEN The vehicle could overturn. HOW TO AVOID

THE

HAZARD Maintain steady speed when

climbing a hill. If all forward speed is

lost: Keep your weight uphill. Apply the brakes. Lock the parking brake when fully stopped. If the vehicle begins rolling

backwards: Keep your weight uphill. Never apply engine power. Never apply the rear brake while rolling backwards. Apply the single-lever brake gradually. When fully stopped, apply the rear brake as well, and then lock

the parking brake. Dismount on uphill side, or to either side if the vehicle is pointed

straight uphill. Turn the vehicle around and remount, following the procedure

described in the owner’s manual. See page 63.

WARNING

Page 29

SAFETY

Operator Safety

POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN

HAPPEN Operating over obstacles could cause loss of control or overturn. HOW TO AVOID THE

HAZARD Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen

trees when possible. If unavoidable, use extreme caution.

POTENTIAL

HAZARD Skidding or sliding. WHAT CAN

HAPPEN Skidding or sliding can cause loss of control. If the tires regain traction unexpectedly, the vehicle could

overturn. HOW TO AVOID THE

HAZARD

On slippery surfaces such as ice, travel slowly and use extra caution to reduce the chance of skidding or sliding out of control.

WARNING

Page 30

SAFETY

Operator Safety

POTENTIAL HAZARD Operating the vehicle through deep or fast-flowing water. WHAT CAN

HAPPEN

Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn.

HOW TO AVOID THE

HAZARD

Avoid operating the vehicle through deep or fast-flowing water. If it’s unavoidable to enter water that exceeds the recommended maximum depth (see page 64), travel slowly, balance your weight carefully, avoid sudden movements, and maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make sudden throttle changes.

Wet brakes may have reduced stopping ability. Always test the brakes after leaving water . If necessary, apply them several times to let friction dry out the pads.

POTENTIAL

HAZARD Improperly operating in reverse. WHAT CAN

HAPPEN

The vehicle could collide with an obstacle or person, resulting in severe injury.

HOW TO AVOID THE

HAZARD

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

WARNING

Page 31

SAFETY

Operator Safety

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

uneven tire pressure. WHAT CAN

HAPPEN

Use of improper tires, or operation of the vehicle with improper or uneven tire pressure, could cause loss of control or accident.

HOW TO AVOID THE

HAZARD

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

Always maintain proper tire pressure as specified in the owner’s manual.

POTENTIAL

HAZARD Operating the vehicle with improper modifications. WHAT CAN

HAPPEN

Improper installation of accessories or modification of the vehicle may cause changes in handling, which could lead to an accident.

HOW TO AVOID THE

HAZARD

Never modify the vehicle through improper installation or use of accessories. All parts and accessories added to the vehicle must be genuine Polaris Industries Inc. or equivalent components designed for use on this vehicle and should be installed and used according to approved instructions. See your authorized Polaris dealer for more information.

WARNING

Page 32

SAFETY

Operator Safety

POTENTIAL HAZARD Overloading the vehicle or carrying/towing cargo improperly. WHAT CAN

HAPPEN

Overloading and towing can cause changes in vehicle handling, which could lead to loss of control or an accident.

HOW TO AVOID THE

HAZARD Never exceed the stated load capacity for this vehicle. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer . Allow a

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

cargo or pulling a trailer. See page 57.

POTENTIAL

HAZARD Operating on frozen bodies of water. WHAT CAN

HAPPEN

Severe injury or death can result if the vehicle and/or the operator fall through the ice.

HOW TO AVOID THE

HAZARD

Never operate the vehicle on a frozen body of water.

WARNING

Page 33

SAFETY

Operator Safety

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

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

CAUTION

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

WARNING

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

WARNING

Page 34

SAFETY

Safety Decals and Locations

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

NEVER operate:

DWithout proper training or instruction. DAt speeds too fast for your skills or the conditions. DOn publ ic roads. A c o llision can occur with another vehicle. DWith a passenger. Passengers affect balance and steering

and increase risk of l osing control.

ALWAYS:

DUse proper riding techni ques to av oid vehicle overturns on

hills and rough terrain and in turns.

DAvoid paved surfaces. Pavement may seriousl y affect han-

dling and control.

LOCATE AND READ OWNER’S MANUAL.

FOLLOW ALL INSTRUCTIONS AND WARNINGS.

IF OWNER’S MANUAL IS MISSING, CONTACT

A POLARIS DEALER FOR A REPLACEMENT.

WARNING

This vehic le is equipped with a back-up alarm.

ALARM MUST SOUND! when operati n g this vehicl e i n reverse.

Failure to maintain a clear view in the direction of travel could result in serious injury or death.

The Operator is responsible for the safe operation of this vehicle.

7170572

DNever operate this vehicle on HILLS steeper than 25 degrees 25°. DUse OVERRIDE for reverse speed limiter with caution. To prevent l oss

of control, never acti vate ov erride button with open throttle.

DREVERSE operation can be dangerous, ev en at low speeds. Steering

becomes difficul t. To prevent flipover, avoid sharp turns. PARKING BRAKE may relax when used for more than 5 minutes. When parking on grades, leave shift in forward.

DUSE ALCOHOL or DRUGS before or while operating this vehicle. DPARKING BRAKE may relax when used for more than 5 minutes .

When parking on grades, leave shift in forward.

7079083E1997, 2000

ALWAYS USE

AN APPROVED

HELMET AND

PROTECTIVE

GEAR

Impropervehicleuse can result in SEVERE INJURY or DEATH.

NEVER USE

ON PUBLIC

ROADS

NEVER CARRY

PASSENGERS

NEVER USE WITH DRUGS OR ALCOHOL

WARNING

7079085

Page 35

SAFETY

Safety Decals and Locations

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

TIRE PRESSURE (PSI): FRONT 4 REAR 3

MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING MACHINE, DRIVER AND CARGO IS 1150 LBS.

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

Read Owner’s Manual for more detailed loading information

WARNING

7079108

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

NEVER operate this vehicle if you are under age 16.

WARNING

Page 36

SAFETY

Safety Decals and Locations

ATTENTION

S Operation of this

vehicle without the filter element will severely damage the engine.

S Clean air filter often, more

frequent cleaning required in dusty conditions.

(Under Seat)

Moving par ts hazard under belt-c lut c h guard. To prevent serious injury, do not oper ate vehicle with guard remov ed.

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

NO STEP

7078689

S Specific carburetor jetting

and adjustments are required depending on temperature and altitude. See your owner’s manual.

Factory setting:

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

C. at 0-900 meters).

7079901

WARNING

DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or t ipov er may r es ult causing sever e injury or death. Tow only from tow hook s or hitc h.

Maximum Rack Loads: Front 90 lbs. Rear 180 Lbs

7070021

WARNING

Page 37

SAFETY

Safety Decals and Locations

MANUFACTURED BY: POLARIS IND

DATE:

VIN:

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

PRINTED IN U.S.A.

7077185

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

7079604

Reverse Speed is limited.

Reverse override is controlled by the override switch.

See your owner’s manual.

OVERRIDE

SWITCH

7079906

7078261

TRAILER MAX WEIGHT: 1225 LBS. (557 KG) ON LEVEL GROUND 850 LB S. (368 KG) UP TO 15° GRADE

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

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

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

7078572

WARNING

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

Page 38

SAFETY

Fuel Safety

Gasoline is highly flammable and explosive under certain conditions.

S Always exercise extreme caution whenever handling gasoline. S Always refuel outdoors or in a well ventilated area with the

engine stopped.

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

area where refueling is performed or where gasoline is stored.

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

off with soap and water and change clothing.

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

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

S Turn the fuel valve off whenever the vehicle is stored or

parked.

The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.

Operate this vehicle only outdoors or in well-ventilated areas.

WARNING

Page 39

SAFETY

Safe Riding Gear

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

1. Helmet

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

Select an approved helmet that meets or exceeds your state’s safety standards and bears either the Department of Transportation (DOT) label, the American National Standards Institute label (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 a helmet face shield offer the best protection for your eyes. They should be kept clean and be of shatterproof design (bearing t he markings z2.1 or VESC 8).

3. Gloves

Gloves with knuckle pads are the best for comfort and protection.

4. Boots

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

5. Clothing

Always wear long sleeves and long pants to protect arms and legs.

Page 40

CONTROLS

Electrical Switches and Indicators

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

WARNING

Override Switch (1) (Reverse Speed Limiter) - This vehicle is equipped with a reverse speed limiter system. To obtain additional power while backing, depress the override button.

Engine Stop Switch (2) - The engine will not start or run when the switch is in t he OFF position. Its purpose is t o 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 will shut off electrical power to the entire vehicle, including lights. To stop the engine, slide the stop switch either right or left to the OFF position.

Horn Switch (3)

Main Switch (4) - To start the engine, slide the stop switch to the

center RUN position and turn the main key switch clockwise past the ON position. Release the key when the engine starts.

RUN

OFFOFF

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

WARNING

Page 41

CONTROLS

Electrical Switches and Indicators

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

1 Transmission Neutral Indicator (Green) 2 Transmission Reverse Indicator (Yellow) 3 High Temp Indicator (Red)

The high temp indicator will light only i f the engine overheats.

4 High Beam Indicator (Blue)

The high beam indicator is located on the left-hand switch.

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

Light Switches

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

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

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

WARNING

Page 42

CONTROLS

Throttle Lever

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

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

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

WARNING

Operating a PTV with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death.

Never start or operate a PTV with a sticking or improperly operating throttle. Always contact your dealer for service if throttle problems arise.

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

WARNING

Page 43

CONTROLS

Brake Lever

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

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

Operating the vehicle with a spongy brake lever can result in loss of brakes, which could cause an accident and lead to serious injury or death. Never operate the vehicle with a spongy-feeling brake lever.

WARNING

Page 44

CONTROLS

Master Cylinder

The brake fluid in the master cylinder (1), which is located on the left handlebar, should be checked before each ride. The fluid l evel can be seen through an indicator window (2) on the top of the master cylinder. This eye will appear dark when the fluid level is full. When fluid needs to be added, the eye will be clear.

NOTE: When checking the fluid level, the vehicle must be on level ground with the handlebars straight. If the fluid level is low, add DOT 3 brake fluid (see page 115).

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

WARNING

Page 45

CONTROLS

Auxiliary Brake

Your Polaris PTV has an auxiliary brake (1) for added safety. It’s located on the inside of the right floor board and is operated by the right foot. The auxiliary brake serves as a backup to the main brake system if the main system becomes inoperative.

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

Brake Fluid Level

Check the brake fluid level frequently for the auxiliary brake system. The reservoir is located inside the right-hand rear fender (2). Maintain the fluid level between the maximum and minimum marks.

Aggressively applying the rear brake when backing down a hill may cause rear tipover , which could result in serious injury or death.

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

WARNING

Page 46

CONTROLS

Parking Brake

Setting the Parking Brake

1. Squeeze and release the brake lever (1) two or three times, then squeeze and hold.

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

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

Important Safeguards

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

ways block the wheels to prevent rolling.

S Always block the wheels on the downhill side of the vehicle if leav-

ing it parked on a hill. Another option is to park the vehicle in a sidehill position.

S Never depend on the parking brake alone for more than five minutes

if the vehicle is parked on a hill. Always block the wheels to prevent rolling.

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

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

WARNING

Page 47

CONTROLS

Engine Fuel and Oil System

Choke

The choke assists in starting a cold engine. Refer to the engine starting procedure on page 53 for correct choke and throttle settings during starting.

Fuel Valve

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

OFF: For vehicle storage and when transporting.

ON: For normal operation.

RES: For reserve supply if main supply is exhausted.

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

Always return valve to the ON position after refueling.

Fuel Tank

The fuel tank filler cap (2) is located directly below the handlebar. Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane.

Fuel Filter

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

RES

OFF

Page 48

CONTROLS

Gear Selector Operation

The transmission gear selector is located on the right side of the vehicle directly above and forward of the engine recoil starter.

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. See your dealer if you experience any shifting problems.

Belt Life

To extend belt life, refrain from continuous operation of the vehicle at the point of engagement (the point at which the vehicle begins to move). C ontinuous operation in this manner increases belt wear.

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

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

CAUTION

Page 49

CONTROLS

Recoil Starter

If the battery is weak and cannot start the engine, use of the recoil starter (1) will allow vehicle operation until repairs can be made. The recoil starter is located next to the right-hand footrest.

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

1. Position the vehicle on a level surface and engage the parking brake. See page 44.

2. Shift the transmission to neutral.

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

4. Pull the rope abruptly to start the engine.

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

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

CAUTION

Page 50

FEATURES

Electronic Speedometer

The electronic speedometer senses vehicle speed from the right front wheel. The electronic speedometer measures distance in miles and kilometers as well as in hours of operation. The speedometer also includes a reverse speed limit function that limits the vehicle’s speed to approximately 7 to 9 mph. See page 38.

To display each mode, press the button on the face of the speedometer once to toggle through the functions, which will display as follows:

Miles 00000.0 M Trip Miles 000.0 M Hours 00000.0 H

Reset Trip Miles

To reset the trip miles, toggle to Trip Miles. Press and hold the button for approximately four seconds.

Programmable Service Reminder

The speedometer has additional features available through a sub-menu:

S Programmable service reminder based on hours S Programmable service reminder based on distance S Change measurement from miles to kilometers or vice versa

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

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

High water pressure may force water into the speedometer and cause damage to the electronic components.

Do not wash the electronic speedometer with a high pressure washer. Wash the unit by hand or with a garden hose.

CAUTION

Page 51

FEATURES

Electronic Speedometer

Access Sub -menu Features

There are two methods for accessing the sub menu.

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

2. Press and hold the button for eight seconds. When the display shows POLArS, release the button.

To display each mode, press the button once to scroll through the four available functions. Each function will be displayed as follows:

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

Change Distance Measurement

1. Access the sub-menu.

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

Set Service Hours

1. Access the sub-menu.

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

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

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

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

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

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

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

Page 52

FEATURES

Electronic Speedometer

Check When Service is Due by Hours

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

1. Access the sub-menu.

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

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

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

Set Service Distance

The procedure for setting Service Distance is the same as for setting Service Hours, but toggle to SET dIS instead of SET hr.

Check When Service is Due by Distance

The procedure for checking Service Distance is the same as for checking Service Hours, but toggle to SET dIS instead of SET hr.

Clear Service Reminder From the Display

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

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

Page 53

OPERATION

Vehicle Break-in Period

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

1. Fill the fuel tank with gasoline. See page 45.

2. Check the oil reservoir level on the dipstick. See page 78. Add Polaris Premium 4 oil if necessary to maintain the level within the normal range (1). See page 115 for part numbers for Polaris-recommended products.

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

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

5. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride inspection checklist. See page 52.

6. Pull only light loads during the break-in period.

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

CAUTION

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

Use of any lubricants other than those recommended by Polaris may cause serious engine damage. We recommend the use of Polaris lubricants for your vehicle.

ADD 8 OZ. NORMAL FULL

Page 54

OPERATION

Pre-Ride Inspection

Use the following checklist to verify t hat your vehicle is in proper operating condition before each use.

Item/Inspection Procedure

1. Tires - check condition and pressures.

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

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

4. Throttle - check for free operation and closing.

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

6. Engine stop switch - check for proper function.

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

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

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

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

11. Riding gear - wear a helmet, goggles and protective clothing.

12. Engine coolant - check for proper level at the recovery bottle.

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

WARNING

Page 55

OPERATION

Starting the Engine

Starting a Cold Engine

1. Position the vehicle on a level surface. Place the transmission in neutral and lock the parking brake.

2. Turn the fuel tank valve to on.

3. Sit on the vehicle.

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

NOTE: The variable choke is fully on when the knob is pulled out all the way. The choke is off when the knob is pushed completely in. The choke can be adjusted gradually, depending on how much choke is needed for starting.

5. Turn the engine stop switch to run.

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

6. Turn the ignition key past the on position to engage the starter. Activate the starter for a maximum of five seconds, releasing the switch when the vehicle starts. If the engine does not start, release the starter and wait five seconds. Activate the starter for another five seconds if necessary. Repeat this procedure until the engine starts.

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

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

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

WARNING

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

CAUTION

Page 56

OPERATION

Starting the Engine

Starting a Warm Engine

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

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

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

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

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

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

Cold Weather Operation

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

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

Page 57

OPERATION

Driving Safely

Driving Procedures

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

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

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

4. Release the parking brake.

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

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

Page 58

OPERATION

Hauling Cargo

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

S REDUCE SPEED AND ALLOW GREATER DISTANCES FOR

BRAKING WHEN CARRYING CARGO.

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

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

S HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROB-

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

S SECURE ALL LOADS BEFORE OPERATING. Unsecured loads

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

S CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE. Car-

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

S OPERATE ONLY WITH STABLE AND SAFELY ARRANGED

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

S USE EXTREME CAUTION when operating with loads extending

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

S DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carry-

ing loads on the front rack.

S DO NOT TRAVEL FASTER THAN THE RECOMMENDED

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

WARNING

Page 59

OPERATION

Hauling Cargo

Your vehicle has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warning labels on the vehicle, and never exceed the weight capacities specified in your owner’ s manual and on safety decals.

Maximum Capacities

(Level Ground)

Front Rack

Cargo

Rear Rack

Cargo

PTV 4x4 800 lbs. (397 kg) 90 lbs. (45 kg) 180 lbs. (90 kg)

Improper loading of the front rack can obstruct the headlight beam, reducing night visibility. Do not obstruct the headlight beam.

Maximum Towing Capacities (Level Ground)

Maximum trailer weight - 1225 lbs. (608 kg); maximum vertical hitch weight - 35 lbs. (17 kg). NOTE: The rear rack capacity and tongue weight should not exceed 180 lbs. (397 kg).

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

2/3

1/3

Page 60

OPERATION

Driving Safely

Turning the Vehicle

Practice making turns at slow speeds.

The Polaris PTV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the i nside tire must slip traction slightly. To turn, steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. This technique alters the balance of traction between the rear wheels, allowing the turn to be made smoothly. The same leaning technique should be used for turning in reverse.

WARNING

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

Page 61

OPERATION

Driving Safely

Driving on Slippery Surfaces

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

1. Slow down when entering slippery areas.

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

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

WARNING

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

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

Page 62

OPERATION

Driving Safely

Driving Uphill

Whenever traveling uphill, follow these precautions:

1. Always travel straight uphill.

2. Avoid steep hills (25_ maximum).

3. Keep both feet on the footrests.

4. Transfer your weight forward.

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

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

25_ Maximum

WARNING

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

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

operating procedures outlined in the owner’s manual.

Page 63

OPERATION

Driving Safely

Driving on a Hillside

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

1. Slow down.

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

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

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

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

WARNING

Page 64

OPERATION

Driving Safely

Driving Downhill

Whenever descending a hill, follow these precautions:

1. Proceed directly downhill.

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

3. Slow down.

4. Apply the brakes slightly toaidinslowing. Familiarize yourself with operation of the auxiliary rear brake pedal in

the event loss of normal service brakes occurs.

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

WARNING

Page 65

OPERATION

Driving Safely

Turning Around on a Hill

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

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

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

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

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

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

6. Lock the parking brake and remount the vehicle from the uphill side, keeping body weight uphill.

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

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

WARNING

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

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

operating procedures outlined in the owner’s manual.

8’

Uphill

Page 66

OPERATION

Driving Safely

Driving Through Water

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

1. Determine water depths and current before crossing.

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

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

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

After running the vehicle in water, it’s critical to have it serviced as outlined in the maintenance chart. See page 70. The following areas need special attention: engine oil, transmission oil, front and rear gearcases, and all grease fittings.

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

If your vehicle becomes immersed, and it’s impossible to take it to a dealer before starting it, follow the steps described on page 100. Have the vehicle serviced by your dealer at the first opportunity.

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

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

CAUTION

Page 67

OPERATION

Driving Safely

Driving Over Obstacles

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

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

WARNING

Page 68

OPERATION

Driving Safely

Driving in Reverse

Follow these precautions when operating in reverse:

1. Always avoid backing downhill.

2. Back slowly.

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

4. Avoid turning at sharp angles in reverse.

5. Never open the throttle suddenly while backing.

NOTE: This vehicle is equipped with a reverse speed limiter. The override switch should be used with caution, as rearward vehicle speed is greatly increased. Do not operate at wide open throttle. Open the throttle just enough to maintain a desired speed.

WARNING

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

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

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

Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust, resulting in engine popping and/or engine damage.

CAUTION

Page 69

OPERATION

Driving Safely

ParkingonanIncline

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

1. Turn the engine off.

1. Place the transmission in gear.

2. Set the parking brake.

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

4. Shut off the fuel supply.

Page 70

-NOTES-

Page 71

NOISE EMISSION CONTROL

SYSTEM REGULATION

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED!

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

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

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

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

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

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

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

4. Lack of proper maintenance.

USFS Approved Spark Arrestor

The muffler on this vehicle was tested and approved in accordance with the USFS Forest Service Standard 5100-1A.

CAUTION

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

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

grass.

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MAINTENANCE AND LUBRICATION

Accessories

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

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

Periodic Maintenance Schedule

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

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

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

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

Maintenance Chart Key

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

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

L Emission Control System Service (California)

J Dealer service item

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

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

Item Hours/

Miles

Frequency Remarks

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

fasteners

Pre-Ride Pre-Ride Inspect all fasteners

Air filter, Pre-cleaner

Pre-Ride Pre-Ride Inspect; clean

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

years Fuel and oil tanks Pre-Ride Pre-Ride Fill to proper levels Throttle Pre-Ride Pre-Ride Check operation Lights Pre-Ride Pre-Ride Check operation Engine stop switch Pre-Ride Pre-Ride Check operation Steering Pre-Ride Pre-Ride Check for free operation

" Air box sediment

tube

Pre-Ride Pre-Ride Drain deposits whenever

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

ply Polaris dielectric grease

to connector when replaced Tail lamp Pre-Ride Pre-Ride Check operation daily; ap-

ply Polaris dielectric grease

to socket when replaced

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

WARNING

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item Hours/

Miles

Frequency Remarks

Air filter/Main element

Weekly Weekly Inspect; replace as needed

" Transmission oil

level

20 hrs Monthly Inspect monthly; change

annually

Battery 20 hrs Monthly Check terminals; clean;

check fluid level

Engine breather 20 hrs Monthly Inspect; replace annually

and as needed

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

gearcase oil (shaft drive)

100 hrs Monthly Check monthly; change

annually

Engine cylinder head and cylinder base fasteners

25 hrs 3 months Inspect (re-torque required

at first service only)

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

cables, etc.

Engine oil level/oil change

100 hrs / 1000 miles

6 months Check level daily; break-in

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

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

WARNING

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item Hours/

Miles

Frequency Remarks

Oil Filter 100 hrs./

1000 mi.

6 months Replace with oil change

Engine breather hose

100 hrs. 6 months Inspect

Carburetor float bowl

50 hrs. 6 months Drain bowl periodically and

prior to storage

J Throttle Cable/ETC

Switch

50 hrs. 6 months Inspect; adjust; lubricate;

replace if necessary

Choke (enricher) cable

50 hrs. 6 months Inspect; adjust; lubricate;

replace if necessary Coolant strength/

pressure test system

100 hrs. 6 months Inspect strength seasonal-

ly; pressure test system

annually

" Front hubs/fluid

check

50 hrs. 6 months Check monthly

Shift linkage 50 hrs. 6 months Inspect; adjust

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

fasteners

" Rear suspension 50 hrs. 6 months Inspect; tighten fasteners

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

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

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

Fuel system 100

hours

12 months Check for leaks at tank

cap, lines, fuel valve, filter,

pump and carburetor; re-

place lines every two years

J Fuel filter 100 hrs. 12 months Replace annually

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

L Emission Control System Service (California)

J Dealer service item

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item Hours/

Miles

Frequency Remarks

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

face

Cooling system hoses

100 hrs. 12 months Inspect

Spark arrestor 100 hrs. 12 months Clean out

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

driven)

100 hrs. 12 months Inspect; clean

Engine mounts 100 hrs. 12 months Inspect

Valve clearance 100 hrs. 12 months Inspect; adjust

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

years

J Brake fluid 200 hrs. 24 months Change every two years

Idle speed As required Adjust Recoil housing As required Drain moisture out after rid-

inginwater

J Toe adjustment As required Periodic inspection; adjust

when parts are replaced

Headlight aim As required Adjust as needed

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

L Emission Control System Service (California)

J Dealer service item

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

WARNING

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Record

Use the following chart to record periodic maintenance.

Maintenance

Interval

Performed

Servicing

Date

Servicing

Dealer

or Person

Remarks

10 hrs. 20 hrs. 50 hrs.

100 hrs.

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

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

Maintenance Chart Key

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

L Use Polaris Premium All Season Grease or grease conforming to

NLGI No. 2

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

periods of storage, or after pressure washing or submerging.

∆ When suspension action becomes stiff, or after washing

Item Lube Method Frequency*

Engine OIl Polaris Premium 4

Synthetic 0W-40

Add to proper level on dipstick. See page 78.

Check level daily.

Brake Fluid DOT 3 Only See page 42. As required; change

every two years or 200 hours

(1) Transmission Oil

Polaris Premium Synthetic gear case lube

See Page 81. Change annually or

at 100 hours

(2) Front Gearcase Oil

GL5 80-90 weight gear lube

See Page 82. Change annually or

at 100 hours

(3) Front Prop Shaft U-joints

FGrease Locate fittings and grease. Every 3 months or

50 hours

(4) Front Propshaft Yoke

FGrease Locate fittings and grease -

3 pumps maximum.

Every 3 months or 50 hours

(3)

(1)

(4)

(2)

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Item Lube Method Frequency*

(5) Hubs Premium Hub

Lube

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

Annually or at 100 hrs.

(6) Ball Joint

LGrease

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

Every 3 months or 50 hours

(7) Front AArm Pivot Shaft

∆LGrease

Locate fitting on pivot shaft and grease with grease gun.

Every 3 months or 50 hours

(8) Upper steering Post Bushing

LGrease

Locate fitting on steering post and grease with grease gun.

Every 3 months or 50 hours

(8)

(6)

(7)

Upper

(5)

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Premium 4 Synthetic Lubricant

Polaris Premium 4 All Season Synthetic engine oil has been specially formulated for use in Polaris 4-cycle engines. It’s a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection. See page 115 for part numbers for Polaris-recommended products.

Premium 4 possesses unsurpassed film strength over the widest possible temperature range. It resists viscosity and frictional breakdown in ambient temperatures from -40° F. to 120° F. (-40° C. to 49° C .) Its exceptional frictional properties result in more efficient operation, more power output and lower fuel consumption.

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

Oil System

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

1. Position the vehicle on a level surface.

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

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

4. Screw the dipstick completely in, then remove it and check to see if the oil level is between the full and add marks. NOTE: The dipstick must be screwed all the way in t o keep the angle and depth consistent.

5. Add oil (see page 115) as needed to bring the level to the normal range (1). Do not overfill.

NOTE: If oil level rises above the full mark, water and/or fuel may be collecting in the tank and the oil should be changed.

CAUTION

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

ADD 8 OZ. NORMAL FULL

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Oil and Filter Ch ange

The recommended oil change interval is 100 hours, 1000 miles (1600 km), or every six months, whichever comes first. Suggested break-in oil change is at 20 hours, 200 miles (320 km), or one month, whichever comes first. Severe use requires more frequent service. Severe use includes continuous duty in dusty or wet conditions and cold weather operation. Severe use cold weather operation is all operation below 10° F. and operation between 10° F. and 30° F. (-12° C. to -1° C.) when most t rips are at a slow speed. Always change the oil filter whenever changing oil.

1. Position the vehicle on a level surface. Clean the area around the drain plug at the bottom of the oil tank and the bottom of the engine.

2. Run the engine for two to three minutes, then turn it off.

3. Place a drain pan beneath the oil tank and remove the drain plug (1). Allow the oil to drain completely.

4. Install a new sealing washer (2) on the oil drain plug. NOTE: The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs, nicks or scratches.

5. Reinstall the drain plug and torque to 14-17 ft. lbs. (19-23 Nm).

6. Disconnect the lower oil delivery hose and remove the screen fitting (3) from the oil tank. Clean and reinstall the fitting, torquing to 25 ft. lbs. (34 Nm). Reattach the oil line. NOTE: The fitting threads must be sealed with Loctitet PST 505 or PTFE seal tape. The fitting must also line up with the mark (4) on the rear side of the oil tank.

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Oil and Filter Ch ange

7. Pl ace shop towels beneath the oil filter. Using an oil filter wrench, turn the filter (1) counterclockwise and remove.

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

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

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

11. After draining, reinstall the drain plug.

12. Remove the dipstick (2) and add two quarts (1.9 l.) of Polaris Premium 4 synthetic oil (see page 115). Reinstall the dipstick. NOTE: If the sump is not drained, add about 1 3/4 quarts initially.

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

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

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

16. Dispose of used filter and oil properly.

CAUTION

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Transmission Lubrication

The transmission fill plug (1) is located on the right side of the machine behind the footwell.

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

With the vehicle on a level surface, remove the fill plug and check the lubricant level. The level should be 1 5/8″ from the top of the fill hole (A). Add Polaris Premium Synthetic Gearcase Lubricant if necessary . See page 115 for part numbers for Polaris-recommended products.

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Transmission Oil Changing Procedure

1. Position the vehicle on a level surface.

2. Remove the four screws on the footwell and gently pull outward for access.

3. Remove the transmission fill plug.

4. Place a drain pan under the bottom right-hand side of the transmission. Remove the transmission drain plug and drain the oil. Discard the used oil properly.

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

6. Add Polaris Premium Synthetic Gearcase Lubricant (see page 115) until oil reaches the bottom of the filler hole.

7. Reinstall the fill plug and check for leaks.

8. Reinstall the footwell.

Front Gearcase Lubrication

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

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

2. View the oil level and add oil if needed. Oil should be kept at the bottom of t he fill plug thread. Use Premium Front Gearcase Fluid (see page 115).

Gearcase Oil Changing Procedure

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

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

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

4. Add 400 ml (13.5 oz.) of Premium Front Gearcase Fluid (see page

115).

5. Reinstall the fill plug and check for leaks.

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Rear Gearcase Lubrication

1. Position the vehicle on a level surface. Remove the fill plug (1) and visually inspect the lubricant level. Lubricant should be kept even with the center of the drillpoint (2), approximately 15/8″ below the top of the fill hole. NOTE: Do not add lubricant to the bottom of the fill plug threads. Use Premium Front Gearcase Fluid (see page 115).

Oil Changing Procedure

1. Place the vehicle on a level surface. Place a drain pan under the drain plug, remove the plug (3), and allow the oil to drain. Discard used oil properly.

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

3. Remove the fill plug and add 10 ounces (300 ml) of Premium Front Gearcase Fluid (see page 115).

4. Check the oil level. Oil level should be kept even with the center of the drill point, approximately 1 5/8″ below the top of the fill hole. NOTE: Do not add oil to the bottom of the fill plug threads.

5. Reinstall the fill plug. Torque to 14 ft. l bs. (19 Nm) and check for leaks.

15/8″

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MAINTENANCE AND LUBRICATION

Engine Cooling System

Recovery Bottle Coolant Level

The recovery bottle (1) is located on the left side of the vehicle. To access the recovery bottle, remove the left side panel as outlined on page 95.

The coolant level must be maintained between the minimum and maximum marks on the recovery bottle. Add coolant as needed.

NOTE: Polaris recommends the use of Polaris Premium 60/40 antifreeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. Polaris Premium 60/40 is already premixed and ready to use (see page 115). Do not dilute with water. Always follow the manufacturer’s mixing recommendations for the freeze protection required in your area.

Cooling System Operation

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

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

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

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MAINTENANCE AND LUBRICATION

Engine Cooling System

Radiator Coolant Level

NOTE: If the cooling system has been drained for maintenance or repair, replace the coolant. If the recovery bottle has run dry, the level in the radiator should be inspected. Add coolant as needed.

1. Access the radiator pressure cap by removing the four screws securing the front rack (1). Remove the front cover (2) by placing your fingers under the front of the cover and pulling upward.

2. Remove the pressure cap.

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

4. Replace the pressure cap and secure the front cover and rack.

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

NOTE: To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water 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. Polaris Premium 60/40 is already premixed and ready to use (see page 115). Do not dilute with water. Always follow the manufacturer’s mixing recommendations for the freeze protection required in your area.

WARNING

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

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MAINTENANCE AND LUBRICATION

Filter Systems

Air Filter Service

Polaris recommends that the air filter be replaced annually. When riding in extremely dusty conditions, replace it more often.

1. Remove the seat.

2. Release the clips securing the air box lid and remove the lid.

3. Loosen the clamp and remove the filter.

4. Remove the fabric type pre-filter (1) from the main filter (2). Wash the pre-filter in soapy water, rinse, and allow it to dry thoroughly.

5. Reinstall the pre-filter over the main filter. Replace the main filter if necessary .

6. Reinstall the filter into the air box and tighten the clamp. Do not over-tighten the clamp or filter damage may occur.

CAUTION

Operating the vehicle without a pre-filter can cause engine damage. Always reinstall the pre-filter before operating.

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MAINTENANCE AND LUBRICATION

Filter Systems

Breather Filter and Hose

1. Remove the clamps and pull the filter (1) out of the hoses. NOTE: It will not be necessary to remove the lower hose from the engine.

2. Inspect the filter for debris. Blow gently through the filter in the direction of the arrow to check for clogging. Replace if necessary.

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

4. Reinstall the filter with the arrow pointing toward the engine. Reinstall the clamps.

Operation of your vehicle without a breather filter can cause engine damage. Always reinstall the breather filter.

CAUTION

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MAINTENANCE AND LUBRICATION

Adjustments

Toe Alignment

Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8″ to 1/4″ toe out.

1. Set the handlebars in a straight-ahead position. NOTE: The steering frog can be used as an indicator of whether the handlebars are straight. The frog should always point straight back from the steering post.

2. Pl ace stands (1) in front of the vehicle, perpendicular to the rear tires. See illustration.

3. Tie an elastic string around the stands, making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in front of the vehicle (2).

4. Measure the distance from the string to t he rim at the front and rear of the front rim (3). Rear measurement should be 1/16″ -1/8″ (.2to.3cm) more than the front measurement.

NOTE: If you discover improper alignment, see your Polaris dealer for service.

WARNING

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

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MAINTENANCE AND LUBRICATION

Adjustments

Steering Inspection

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

Camber and Caster

The camber and caster are non-adjustable.

Rear Spring Adjustment

The rear shock absorber spring is adjusted by rotating the adjuster in the direction required t o increase or decrease spring tension.

NOTE: Accessory springs are available through your P olaris dealer.

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MAINTENANCE AND LUBRICATION

Adjustments

Handlebar Adjustment

Your PTV has handlebars that can be adjusted for a personal fit.

1. Remove the upper headlight pod.

2. Loosen the four handlebar block bolts (1).

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

4. Lightly tighten each bolt equally to prevent uneven gaps in the block.

5. Torque the handlebar adjuster block bolts to 10-12 ft. lbs. (14-16 Nm).

6. Replace the headlight pod.

WARNING

Improper adjustment of the handlebars or incorrect torquing of the adjuster block bolts can cause limited steering or loosening of the handlebars, resulting in loss of control and possible serious injury or death. Perform the handlebar adjustment exactly as outlined.

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MAINTENANCE AND LUBRICATION

Adjustments

Brake Adjustments

Front Brakes

The front brakes are hydraulic disc brakes. They’re activated by moving the brake lever t oward the handlebar. These brakes are self-adjusting.

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

1. Always keep brake fluid at an adequate level (see page 42). Under normal functioning the diaphragm extends into the reservoir as fluid l evel drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced. Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation. Use Polaris DOT 3 brake fluid (see page 115).

2. Check the brake system for fluid leaks.

3. Check the brakes for excessive travel or spongy feel.

4. Check the friction pads for wear, damage and looseness.

5. Check the security and surface condition of the disc.

NOTE: Pads should be changed when worn to 3/64″ (.1 cm), or about the thickness of a U.S. dime.

WARNING

3/64″ (.1 cm)

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MAINTENANCE AND LUBRICATION

Adjustments

Brake Adjustments

Rear Brake

The transmission brake is a hydraulic disc brake and is activated by the same lever that activates the front brake system. The transmission brake system is self-adjusting and requires no maintenance other than periodic checks of the pads for wear.

Pads should be changed when worn to 3/64″ (.1 cm), which is about the thickness of a U.S. dime.

Inspect the brake disc spline and pad wear surface for excessive wear.

Auxiliary Brake

Your vehicle’s auxiliary brake system is intended to be used as a backup for the main brake system. Should the main system fail, the rear brake can be activated by depressing the foot pedal on the inside of the right footrest. The hydraulic auxiliary brake system will not require adjustment.

NOTE: Since this is a rear brake only, it will not be as effective as the all wheel system.

3/64″ (.1 cm)

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MAINTENANCE AND LUBRICATION

Adjustments

Carburetor/Engine Idle RPM Adjustment

If the engine idle speed is not satisfactory and all other conditions are favorable, the carburetor can be adjusted as follows:

1. Start the engine and allow it to warm up for approximately five minutes.

2. Place the transmission in gear and lock the parking brake.

3. Adjust the carburetor idle screw (1) in or out until the desired idle RPM is reached. Turning the screw in (clockwise) will raise RPM. Turning the screw out (counterclockwise) will lower RPM.

Throttle Cable Freeplay Adjustment

Throttle cable freeplay is adjusted at the handlebar.

1. Slide the boots (1) off the inline cable adjuster sleeve (2). Loosen the adjuster locknut (3).

2. Turn the adjuster until 1/16″ to 1/8″ freeplay is achieved at the thumb lever. Flip the throttle lever several times to confirm the adjustment.

3. Tighten the locknut and slide the boots over the cable adjuster until they touch at the middle point of the adjuster.

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MAINTENANCE AND LUBRICATION

Adjustments

Carburetor Adjustments

IMPORTANT: Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for each 1000-foot (304.8 m) increase in elevation. Although this power cannot be regained, adjustments t o the carburetor and drive system can be made to allow more efficient operation. Optional jets, available from your Polaris dealer, are required for operation above 6,000 feet and temperatures below +40 degrees F. (4 degrees C.)

NOTE: Continuous operation of the engine without proper jetting when required can cause poor performance, overheating or engine damage. See your Polaris dealer for more information about jetting the ATV for conditions in your area.

NOTE: Pilot screws are sealed with metal plugs and are serviceable only by Polaris dealers.

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MAINTENANCE AND LUBRICATION

Adjustments

Side Panel Removal

NOTE: Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times.

1. Remove the seat.

2. Grasp the rear of the s ide panel near the rear cab. With a quick and firm motion, pull the panel forward and outward to disengage the two rear tabs.

3. Place your hand on top of the side panel behind the fuel tank. With a quick and firm motion, push down on the side panel to disengage the top rear twotabs. Thenpulluponthe side panel to disengage the front upper and lower tabs.

4. To reinstall the side panel, align the panel tabs with the slots on the front cab. Push the panel upward and forward until the tabs lock. Bend the rear of the side panel and insert the two tabs into the rear cab.

Step 2

Step 3

Step 4

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MAINTENANCE AND LUBRICATION

Adjustments

Tire Tread Depth

Always replace tires when tread depth is worn to 1/8″ (.3 cm) or less. See illustration.

Wheel Removal

1. Stop the engine, place the transmission in gear and lock the parking brake.

2. Loosen the wheel nuts slightly.

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

4. Remove the wheel nuts and remove the wheel.

Operating your PTV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death.

Maintain proper tire pressure as described on the decal on your PTV and in the owner’s manual.

Always use original equipment size and type when replacing tires. Make sure the wheels are installed properly as outlined in the

owner’s manual. Always replace tires when the tread depth measures 1/8″ (.3 cm)

or less.

WARNING

1/8I (.3 cm)

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MAINTENANCE AND LUBRICATION

Adjustments

Wheel Installation

1. With the transmission in gear and the parking brake locked, place the wheel on the wheel hub. Be sure the valve stem is toward the outside and the rotation arrows on the tire point toward forward rotation.

2. Attach the wheel nuts and finger tighten them. NOTE: Make sure the tapered end of the rear wheel nut goes into the taper on the wheel (1).

3. Lower the vehicle to the ground.

4. Torque the wheel nuts to 20 ft. lbs. (27 Nm).

Front Wheel Hub Tightening

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

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MAINTENANCE AND LUBRICATION

Spark Plugs

S Use NGK BKR5E spark plugs. S Proper electrode gap is .036″ (.9 mm) S Spark plug torque is 14 ft. lbs. (19 Nm).

Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color.

1. Normal

The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service.

NOTE: The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetion adjustments.

2. Wet Fouled

The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. General causes of fouling are excessive oil, use of non-recommended i njection oil, improper use of the choke, or incorrect carburetion adjustments.

Spark Plug Removal and Replacement

1. Remove the spark plug cap.

2. Using the special wrench provided in the tool pouch, rotate the spark plug counterclockwise to remove.

3. Reverse the procedure for spark plug installation. Torque to 14 ft. lbs. (19 Nm).

Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs.

CAUTION

WARNING

A hot exhaust system and engine can cause serious burns. Wear protective gloves when removing a spark plug for inspection.