Polaris Scrambler 500 4x4 2004 Owner's Manual

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

The engine exhaust from this

product contains chemicals known

to cause cancer, birth defects or

other reproductive harm.

WARNING

1

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Copyright 2003 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor
discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference
use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or
reuse of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited. Printed in U.S.A.

3

WELCOME

Thank you for purchasing a P olaris 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 Watercraft
S Victory motorcycles
S RANGER utility vehicles

Polaris Professional Series Workmobilest

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

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

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

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

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

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

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TABLE O F CONTENTS

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

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

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

FEATURES AND CONTROLS 37...............

OPERATION 49..............................

EMISSION CONTROL SYSTEMS 68............

MAINTENANCE AND LUBRICATION 69.........

SPECIFICATIONS 114........................

POLARIS PRODUCTS 117.....................

TROUBLESHOOTING 118.....................

WARRANTY 122..............................

INDEX 125...................................

6

VEHICLE IDENTIFICATION NUMBERS

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

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

NOTE: Record your vehicle’s ID numbers and key number (2) in the
spaces provided.

1

31XX

2

Frame VIN:

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

Vehicle Model Number:

Key Number:

7

SAFETY

Operator Safety

Age Restrictions

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

Know Y our Vehicle

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

Safety T raining

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

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

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

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

WARNING

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

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

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

8

SAFETY

Operator Safety

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

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

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 machine.

CAUTION

NOTE

A note will alert you to important information or instructions.

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

CAUTION

WARNING

9

SAFETY

Operator Safety

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

procedures described.

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

course. Beginners should receive training from a certified instructor.

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

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

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

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

walks, driveways, parking lots, and streets.

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

a dirt or gravel road.

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

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

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

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

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

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

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

rests of the ATV during operation.

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

miliar t errain. Be alert to changing terrain conditions.

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

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

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.

10

SAFETY

Operator Safety

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

it’ s been involved in an accident.

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

Practice on smaller hills before attempting larger hills.

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

rain carefully before ascend a hill. Never climb hills with excessive­ly slippery or loose surfaces. Shift your weight forward. Never open
the throttle suddenly or make sudden gear changes. Never go over
the 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 ATV. Never attempt to turn the ATV
around on any hill until you’ve mastered (on l evel ground) the turn­ing technique outlined in this manual. Avoid crossing the side of a
steep hill when possible.

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

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

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

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

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

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

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

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

11

SAFETY

Operator Safety

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

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

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

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

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

always maintain proper tire pressure.

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

sories.

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

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

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

prevent unauthorized use or accidental starting.

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

Equipment Modifications

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

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

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

12

SAFETY

Operator Safety

POTENTIAL HAZARD

Operating this ATV without proper instruction.

WHAT CAN

HAPPEN

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

HOW TO AVOID THE

HAZARD

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

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

POTENTIAL

HAZARD

Failure to follow the age recommendations for this ATV.

WHAT CAN

HAPPEN

Severe injury and/or death could occur if a child under the
minimum age recommendation operates an A TV.

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

HOW TO AVOID THE

HAZARD

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

WARNING

WARNING

13

SAFETY

Operator Safety

POTENTIAL HAZARD

Carrying a passenger on an A TV.

WHAT CAN

HAPPEN

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

HOW TO AVOID THE

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

14

SAFETY

Operator Safety

POTENTIAL HAZARD

Operating an ATV on paved surfaces, including sidewalks,
paths, parking lots, and driveways.

WHAT CAN

HAPPEN

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

HOW TO AVOID THE

HAZARD

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

WARNING

15

SAFETY

Operator Safety

POTENTIAL HAZARD

Operating this ATV on public streets, roads or highways.

WHAT CAN

HAPPEN

The ATV could collide with another vehicle.

HOW TO AVOID THE

HAZARD

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

WARNING

16

SAFETY

Operator Safety

POTENTIAL HAZARD

Operating this ATV without wearing an approved helmet, eye
protection and protective clothing.

WHAT CAN

HAPPEN

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

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

HOW TO AVOID THE

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

17

SAFETY

Operator Safety

POTENTIAL HAZARD

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

HOW TO AVOID THE

HAZARD

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

POTENTIAL

HAZARD

Operating the ATV at excessive speeds.

WHAT CAN

HAPPEN

Excessive speed increases the operator’s chance of losing
control of the ATV, which can result in an accident.

HOW TO AVOID THE

HAZARD

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

WARNING

WARNING

18

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

19

SAFETY

Operator Safety

POTENTIAL HAZARD

Failure to inspect the ATV before operating.

Failure to properly maintain the ATV.

WHAT CAN

HAPPEN

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

HOW TO AVOID THE

HAZARD

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

Always follow the inspection and maintenance procedures and
schedules 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 ATV.

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 ATV during operation.

WARNING

WARNING

20

SAFETY

Operator Safety

POTENTIAL HAZARD

Failure to use extra caution when operating the ATV 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

21

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 ATV on such terrain.

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

WARNING

22

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 ATV or for your
abilities. Never operate the ATV on hills steeper than 25_.

Practice on smaller hills before attempting large hills.

WARNING

WARNING

23

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 operate the ATV on hills steeper than 25_.

Never climb hills with excessively slippery or loose surfaces.

Shift your weight forward.

Never open the throttle suddenly while traveling uphill. The ATV
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

24

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. NOTE: A special technique
is required when braking while traveling downhill. See page

62.

Always check the terrain carefully before you descending a hill.

Shift your weight backward.

Never travel down a hill at high speed.

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

WARNING

25

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 ATV 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 ATV.

WARNING

26

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 single lever brake gradually.

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

If the ATV begins rolling

backwards:

Keep weight uphill.

Never apply engine power.

Never apply the auxiliary rear brake while rolling backwards.

Apply the single-lever brake gradually.

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

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

Turn the ATV around and remount, following the procedure
described in the owner’s manual. See page 63.

WARNING

27

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 and
always follow proper procedures as outlined in the owner’s
manual.

POTENTIAL

HAZARD

Skidding or sliding.

WHAT CAN

HAPPEN

Skidding or sliding can cause loss of control.

If the tires regain traction unexpectedly , the ATV 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

WARNING

28

SAFETY

Operator Safety

POTENTIAL HAZARD

Operating the ATV 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 A TV 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 ATV 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 ATV. When it’s safe to proceed, back
slowly .

WARNING

WARNING

29

SAFETY

Operator Safety

POTENTIAL HAZARD

Operating this ATV with improper tires, or with improper or
uneven tire pressure.

WHAT CAN

HAPPEN

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

HOW TO AVOID THE

HAZARD

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

Always maintain proper tire pressure as specified in the owner’s
manual and on safety decals.

POTENTIAL

HAZARD

Operating the ATV with improper modifications.

WHAT CAN

HAPPEN

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

HOW TO AVOID THE

HAZARD

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

WARNING

WARNING

30

SAFETY

Operator Safety

POTENTIAL HAZARD

Overloading the ATV 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 ATV.

Cargo should be properly distributed and securely attached.

Reduce speed when carrying cargo or pulling a trailer. Allow a
greater distance for braking.

Always follow the instructions in the owner’s manual for carrying
cargo or pulling a trailer. See page 54.

POTENTIAL

HAZARD

Operating on frozen bodies of water.

WHAT CAN

HAPPEN

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

HOW TO AVOID THE

HAZARD

Never operate the ATV on a frozen body of water. If you’re
confident that the ice is thick enough and sound enough to
support the machine and its operator, as well as the force
created by a moving vehicle, exercise extreme caution.

WARNING

WARNING

31

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

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

32

SAFETY

Fuel Safety

Gasoline is highly flammable and explosive under certain
conditions.

S Always exercise extreme caution whenever handling gaso-

line.

S Always refuel with the engine stopped, and outdoors or in a

well ventilated area.

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

area where refueling is performed or where gasoline is
stored.

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

off with soap and water and change clothing.

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

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

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

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

WARNING

33

SAFETY

Safety Decals and Locations

Warning decals have been placed on the ATV for your protection. Read
and follow the instructions of the decals on the ATV carefully. If any
of the decals depicted in this manual differ from the decals on your
ATV, always read and follow the instructions of the decals on the ATV.

If any 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.

7079604

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.

DNever operate this vehicle on HILLS steeper than 25 degrees

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

DREVERSE operation can be dangerous, evenat lowspeeds. Steering be-

comes difficult. To prevent flipover, avoid sudden braking or sharp turns.

DUse OVERRIDE for reverse speed limiter with caution. To prevent loss

of control, never activate override button with open throttle.

DPA RK ING BRAKE may relax when used for more than 5 minutes. When

parking on grades, leave shift in forward.

WARNING

7079085

25°

.

S Moving parts hazard under belt- clutc h guar d. To

prevent s erious injury, do not operate vehicle
with guard remov ed.

S 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

WARNING

34

SAFETY

Safety Decals and Locations

WARNING

7077920

WARNING

Improper A TV use can result in SEVERE INJUR Y or DEA TH

ALWAYS USE

AN APPROVED

HELMET AND
PROTECTIVE

GEAR

NEVER USE

ON PUBLIC

ROADS

NEVER CARRY

PASSENGERS

NEVER USE
WITH DRUGS
OR ALCOHOL

NEVER operate:

ALWAYS:

35

SAFETY

Safety Decals and Locations

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

NEVER operate this ATV i f you are
under age 16.

WARNING

7078253

ALL WHEEL

DRIVE

SWITCH

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

7079780

Under Seat

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

Torque Nut on Eccentric Bolts:
To 30 Ft. Lbs. (For models
without a hitch).
To 40 Ft. Lbs. (For models with
ahitch).

7078572

MANUFACTURED
BY: POLARIS IND. INC.

DATE:

VIN:

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

7171492

CE VÉHICULE ES T UN VÉHICULE TO UT TERRAIN QUI NiEST
PAS DEST I NÉ À ÊTRE UTILIS É SUR LES CHEMINS PUBLICS.

Canadian Certification Decal

36

SAFETY

Safe Riding Gear

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

1. Helmet

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

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

3. Gloves

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

4. Boots

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

5. Clothing

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

1

2

3

4

5

37

FEATURES AND CONTROLS

Electrical Switches

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 gain additional power while backing,
depress the override switch. NOTE: The override
switch also allows activation of AWD in reverse, if
the AWD switch is on.

Main Switch (2) - To start the engine, slide the stop switch to the
center RUN position and turn the main key switch clockwise past the
ON position. Release the key when t he engine starts. NOTE: Turn off
the main switch to end all electrical power to the vehicle, including the
lights.

Engine Stop Switch (3) - The engine will not start or run when the
switch is in its OFF position. Its purpose is to provide the operator
with a quick means of engine shutdown in case of an emergency. To
stop the engine, slide the stop switch either right or left to the OFF
position. NOTE: Turning off the engine stop switch will shut off all
electrical power to the vehicle, including the lights.

1

2

3

RUN OFFOFF

3

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

38

FEATURES AND CONTROLS

Light Switches

The light switch is located on the left
handlebar (1). It’s used to turn the
lights on and off and to switch the
lights from high beam to low beam.
NOTE: The lights won’t work unless
the key is in the ON position and the
shut-off switch is in the RUN position.

Indicator Lights

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

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

1. Transmission Neutral Indi cator

2. Transmission Reverse Indi cator

3. HighTempWarning(displays if engine overheats)

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

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

WARNING

1

1

2

3

39

FEATURES AND CONTROLS

Throttle Lever

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

This ATV is equipped with Polaris
Electronic Throttle Control (ETC),
which is designed to reduce t he risk of a frozen or stuck throttle. If the
throttle cable should stick i n 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

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

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

Failure to check or maintain proper operation of the throttle
system can result in an accident if the throttle lever sticks during
operation.

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

WARNING

1

40

FEATURES AND CONTROLS

Brake Lever

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

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

Operating the ATV with a spongy brake lever can result in loss
of braking, which could cause an accident.

Never operate the ATV with a spongy-feeling brake lever.

WARNING

1

41

FEATURES AND CONTROLS

Brakes

Check the brake fluid level in the
master cylinder before each use of
the ATV. The master cylinder (1) is
located on the left handlebar.

The fluid level 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 ATV must be on level
ground with the handlebars straight. If the fluid level is low add DOT 3
brake fluid only. DO NOT OVERFILL. See page 117 for the part
numbers of Polaris products.

1

2

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

WARNING

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

WARNING

42

FEATURES AND CONTROLS

Parking Brake

Setting the Parking Brake

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

2. Push the park brake lock (1)
forward to engage the brake.
Release the brake lever.

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

Important Safeguards

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

ways block the wheels to prevent rolling.

S Always block the wheels on the downhill side of the ATV if leaving

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

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

hill. Always block the wheels to prevent rolling.

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

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

WARNING

1

43

FEATURES AND CONTROLS

Auxiliary Brake

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

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

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

Aggressively applying the auxiliary rear brake when backing
downhill 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

1

44

FEATURES AND CONTROLS

Choke

The choke assists in starting a cold engine. Refer to the engine starting
procedure on page 51 for correct choke and throttle settings during
starting.

Fuel Valve

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

OFF: For vehicle storage and when transporting.

ON: For normal operation.

RES: For reserve supply if m ain
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 the 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. Refer to the
specifications section at the rear of this
manual for tank capacity.

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.

2

1

45

FEATURES AND CONTROLS

Automatic Transmission Gear Selector

The transmission gear selector (1)
is located on the right side of the
vehicle.

F: Forward

N: Neutral

R: Reverse

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

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

1

F

N

R

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

46

FEATURES AND CONTROLS

Recoil Starter

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

Polaris 4-cycle engines are
equipped with automatic
decompressors. This makes recoil
starting possible by reducing the amount of compression during
starting. The decompressor senses when the engine is spinning fast
enough to start and restores compression when running.

1. Position the vehicle on a level surface and lock the parking brake
(see page 42).

2. Shift the transmission into neutral.

3. Make sure the engine stop switch is set to RUN and the main key
switch is in the ON position. NOTE: If the engine is cold, use the

choke as outlined on page 51.

4. Grasp the recoil starter rope handle (2) firmly and pull slowly so

you can feel the engine strokes. NOTE: Every other stroke will
be a “compression stroke” and will make the rope harder to pull.
When a compression stroke is found, continue pulling the rope just
until the engine rolls past the stroke, then stop pulling immediately.

5. Allow the recoil rope to rewind into the recoil assembly, then pull

the rope abruptly and forcefully to start the engine.

6. Repeat steps 4-5 if necessary.

1

2

Extending the recoil starter rope until it stops can 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

47

FEATURES AND CONTROLS

All Wheel Drive (AWD) System

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

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

NOTE: The override switch allows activation of AWD in reverse if
the AWD switch is on. See page 37.

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

Engaging Wheel Hubs

The AWD switch may be turned on or off while the vehicle is moving.
Initially, t he vehicle’s electronic system will not enable the AWD until
the engine RPM is below 3100. Once enabled, the AWD remains
enabled until the AWD switch is turned off. If the switch is turned off
while the front hubs are moving, the hubs will not disengage until the
rear wheels regain traction.

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

1

2

Switching to AWD while the rear wheels are spinning may
cause severe drive shaft and hub damage. Always switch to
AWD while the rear wheels have traction or are at rest.

CAUTION

48

FEATURES AND CONTROLS

All Wheel Drive (AWD) System

Disengaging Wheel Hubs

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

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

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

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

Operating with only one front hub engaged could result in loss
of control, accident, and severe injury or death. When hub
engagement symptoms are present, use the disengaging
procedure before proceeding.

WARNING

49

OPERATION

Break-In Period

The break-in period for your new 4-cycle Polaris ATV is defined as the
first ten hours of operation, or the time it takes to use the first two full
tanks of gasoline. No single action on your part is as important as
following the procedures for a proper break-in. Careful treatment of a
new engine will result in more efficient performance and l onger life for
the engine. Perform the following procedures carefully.

1. Fill the fuel tank with
gasoline (see page 44).

2. Check the oil level on
the dipstick (see page

79). Add the
recommended oil as needed to maintain the oil level in the normal
operating range (1).

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

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

5. Perform regular checks on fluid levels, controls and areas outlined
on the daily pre-ride inspection checklist. See page 50.

6. Pull only light loads.

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

ADD 8 OZ. NORMAL FULL

1

50

OPERATION

Pre-Ride Inspection

Use the following checklist to verify that your ATV is in proper
working condition before each use.

Item/Inspection Procedure

1. Tires - Check condition and pressures.

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

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

4. Throttle - Check for free operation and closing.

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

6. Engine stop switch - Check for proper function.

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

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

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

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

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

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

13. Engine coolant - Check for proper level at the recovery bottle.

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

WARNING

51

OPERATION

Starting the Engine

Starting a Cold Engine

1. Place the transmission in neutral
and lock the parking brake.
Make sure the fuel tank valve is
on.

2. Sit on the vehicle and pull the
choke knob out until it stops (1).
NOTE: If the knob doesn’t stay
where positioned, increase the
tension by rotating the tension
adjusting nut (2) clockwise.

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

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

1

2

52

OPERATION

Starting the Engine

Starting a Cold Engine

3. Move the engine stop switch to RUN. NOTE: Do not press the
throttle while starting the engine.

4. Turn the ignition key past the ON position to engage the starter.
Activate the starter for a maximum of five seconds, releasing the
key when the engine starts. If the engine does not start, release the
key and wait five seconds. Then activate the starter for another
five seconds. Repeat this procedure until the engine starts.

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

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

53

OPERATION

Starting the Engine

Starting a Warm Engine

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

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

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

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

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

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

Cold Weather Operation for 4-Cycle Engines

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

54

OPERATION

Hauling Cargo

Accessory racks and hitches are available from your Polaris dealer.
Always read and understand the load distribution warnings on all
warning labels, and never exceed the specified weight capacities for the
vehicle.

Maximum Towing Capacities

Refer to the specifications at the rear of this manual for towing
capacities. When towing, reduce the rear rack cargo load capacity by
the amount of trailer tongue weight.

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

2/3

1/3

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 the procedures and precautions
outlined in this owner’s manual and on safety decals when
hauling cargo.

WARNING

55

OPERATION

Hauling Cargo

Procedures and Precautions

S REDUCE SPEED AND ALLOW GREATER DISTANCE FOR

BRAKING WHEN HAULING CARGO.

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

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

S LOADS MUST BE CARRIED AS LOW ON THE RACKS AS

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

S ALL LOADS MUST BE SECURED BEFORE OPERATING. Un-

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

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 HEAVY LOADS CAN CAUSE BRAKING AND CONTROL

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

S EXTREME CAUTION MUST BE USED when operating with

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

S DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carry-

ing loads on the front rack.

S DO NOT TRAVEL F A STER 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.

56

OPERATION

Driving Safely

Driving Procedures

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

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

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

4. Release the parking brake.

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

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

57

OPERATION

Driving Safely

Making Turns

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

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

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

WARNING

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

58

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 t he skid
and shifting your body weight forward.

4. Driving with AWD engaged can assist in controlling the vehicle in
slippery areas.

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

CAUTION

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.

59

OPERATION

Driving Safely

Sidehilling

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

60

OPERATION

Driving Safely

Driving Up hill

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.

61

OPERATION

Driving Safely

Driving Up hill

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 t he vehicle.

If all forward speed is lost:

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

auxiliary brake as well, then lock the park brake.

If the ATV begins rolling backwards:

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

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

Dismount on uphill side, or to either side if ATV is pointed straight
uphill. Turn the ATV around and remount, following the procedure
described on page 63.

62

OPERATION

Driving Safely

Driving Do w nhill

Whenever descending a hill, follow these precautions:

1. Proceed directly downhill.

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

3. Slow down.

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

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

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

WARNING

63

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 transmission in forward and shut off the engine.

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

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

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

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

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

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

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

64

OPERATION

Driving Safely

Driving Through Water

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

1. Determine water
depths and current
before crossing.

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

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

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

After running the vehicle in water, it’s critical to have it serviced as
outlined in the maintenance chart. See page 69. 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 102. Have
the vehicle serviced by your dealer at the first opportunity.

1

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

65

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

66

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

67

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.

68

EMISSION CONTROL SYSTEMS

Noise Emission Control System

Do not modify the engine, intake or exhaust components, as doing so
may affect compliance with state and local noise level requirements.

Spark Arrestor

Your Polaris vehicle has a spark arrestor that was tested and approved
in accordance with the USDA Forest Service Standard 5100-1C.
Federal law requires that this spark arrestor be installed and functional
when the vehicle is operated on public lands.

Crankcase Emission Control System

This engine is equipped with a closed crankcase system. Blow-by
gases are forced back to the combustion chamber by the intake system.
The system does not allow the blow-by gases to enter the atmosphere.

Exhaust Emission Control System

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

Adjustment to engine idle is the
only adjustment Polaris
recommends that the operator
perform. Any other adjustments
should be performed by an
authorized Polaris dealer.

The emissions label (1) is located
on the recoil cover.

1

69

MAINTENANCE AND LUBRICATION

Accessories

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

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

Periodic Maintenance Schedule

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

Maintenance intervals in the following charts are based upon average
riding conditions and an average vehicle speed of approximately 10
miles per hour. Vehicles subjected to severe use, such as operation in
wet or dusty areas, should be i nspected 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 S ervice (California - 4-Cycle)

NOTE: Some 4-cycle models may have an additional California­only emissions warranty.

J Dealer service item.

70

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

"

L

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

Drive chain Pre-Ride Pre-Ride Check condition/slack

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

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

71

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item Hours/

Miles

Frequency Remarks

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

ply Polaris dielectric grease
to socket when replaced

"

L

Air filter,
main element

Weekly Weekly Inspect; replace as needed

" Transmission oil 20 hrs. Monthly Inspect level monthly;

change annually

Battery 20 hrs. Monthly Check terminals; clean

"

L

Engine breather
filter

20 hrs. Monthly Inspect; replace annually

and as needed

J Brake pad wear 10 hrs. Monthly Inspect periodically

" Front and rear

gearcase oil

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.

"

L

Engine oil level/oil
change

100 hrs./
1000 mi.

6 months Check level daily; break-in

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

"

L

Oil filter 100 hrs./

1000 mi.

6 months Replace with oil change

L

Engine breather
hose

100 hrs. 6 months Inspect

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

L Emission Control System Service (California)

J Dealer service item

72

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item Hours/

Miles

Frequency Remarks

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

L

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 (AWD)

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

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

bricate if needed

" Rear axle 50 hrs 6 months Inspect bearings

L

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

J

L

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

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

73

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item Hours/

Miles

Frequency Remarks

J

L

Fuel system 100 hrs. 12 months Check for leaks at tank

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

J Fuel filter 100 hrs. 12 months Replace annually

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

face

Cooling system
hoses

100 hrs. 12 months Inspect

" Front hubs (AWD) 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

J

L

Valve clearance 100 hrs. 12 months Inspect; adjust

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

Spark arrestor 300 hrs. 36 months Clean out

L

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

74

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

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

Lubrication Chart Key

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

L Polaris Premium All Season Grease or grease conforming to NLG

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

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

periods of storage, or after pressure washing or submerging

∆ When suspension action becomes stiff, or after washing

Item Lube Method Frequency

4-Cycle
Engine

Premium 4
Synthetic 0W40

Add to proper level on dip­stick.

Check level daily

Brakes DOT 3 fluid only Maintain level between fill

lines. See page 41.

As required;
change every two
years or 200
hours

Drive chain(s) O-ring chain

lube or SAE
80/90

Lubricate. As needed, before

each use in wet
conditions

(1) Transmission AGL Synthetic

Gearcase Lube

See Page 82. Change annually

or at 100 hours

(2) Front
Gearcase

Angle Drive
Fluid

See Page 83. Change annually

or at 100 hours

(3) Front Prop
Shaft U-joints

FGrease Grease fittings. 3 months/50

hours

(4) Front Prop
Shaft Yoke

FGrease Grease fittings

(3 pumps maximum).

3 months/50
hours

(5) Front Drive
Axle (U Joint)

FGrease Locate grease fitting and

grease with grease gun.

Every 3 months or
50 hours

(6) Swing Arm
Bushings

"L Grease

Locate fittings on swing arm
and grease with grease gun.

Monthly or at 20
hours

(7) Tie Rod Ends

"L∆ Grease

Lift boot, clean away dirt and
grease, apply fresh grease
by hand and reassemble.

Semi-annually

(8) Front 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.

(9) Ball Joint

"L Grease

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

Every 3 months or
50 hours

(10) A-Arms

"L∆ Grease

Locate fittings and grease. Semi-annually

75

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

(3)

(1)

(4)

(2)

(5)

(9)

(8)

(6)

(10)

(7)

4 or 8 o’clock

position- (end view)

76

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.

77

MAINTENANCE AND LUBRICATION

Periodic Maintenance Record

Use the following chart to record periodic maintenance.

Maintenance

Interval

Performed

Servicing

Date

Servicing

Dealer

or Person

Remarks

78

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Premium 4 Synthetic Oil

Polaris Premium 4 All Season Synthetic engine oil has been specially
formulated for use in Polaris 4-cycle engines. It’s a fully synthetic,
high performance, multi-viscosity oil designed to provide the ultimate
in lubrication performance and protection. See page 117 for the part
numbers of Polaris 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. Its
exceptional frictional properties result in more efficient operation, more
power output and lower fuel consumption.

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

CAUTION

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

79

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Engine Oil Check

1. Position the machine on a level surface.

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

3. Remove the dipstick (1),
which is located on the left
side of the vehicle.

4. Wipe the dipstick dry with a
clean cloth. Reinstall it and
screw it completely in.
NOTE: The dipstick must
be screwed completely i n to
keep the angle and depth of
the stick consistent.

5. Remove the dipstick and
read the oil level.
Maintain the oil level in
the normal operating
range (2). Do not overfill.

1

ADD 8 OZ. NORMAL FULL

2

80

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Oil and Filter Change

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

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

Always change the oil filter whenever changing oil.

1. Position the vehicle on a level
surface.

2. Clean the area around the drain
plug (A), which is located on the
bottom of the oil tank.

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

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

5. Allow the oil to drain completely.

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

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

8. Disconnect the lower oil delivery hose. Remove the fitting (C)
from t he oil tank. Clean the fitting screen. Reinstall the fitting
screen, torquing to 14-17 ft. lbs. (19-23 Nm). Reattach the oil line
and torque the hose clamp (D) to 25 in. lbs. (2.8 Nm).

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

CAUTION

B

A

C

D

81

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Oil and Filter Change

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

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

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

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

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

14. Remove the dipstick (2) and add the recommended oil. NOTE: If
the sump is not drained, add about 1 3/4 quarts (1.66 l) initially.

15. Reinstall the dipstick.

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

17. S t art the engine and let it idle for one to two minutes. Stop the
engine and inspect for leaks.

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

19. Dispose of used filter and oil properly.

2

1

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

CAUTION

82

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Transmission Oil Check

The transmission lubricant level should be checked every six months or
1000 miles (1600 km), whichever comes first. Maintain the oil level at
the bottom of the fill hole threads. Change transmission oil annually.
We recommend the use of AGL Synthetic Gearcase Lubricant. See
page 117 for the part numbers of Polaris products.

1. Position the ATV on a level
surface and remove the fill plug (1),
which is located on the right side
of the machine, behind the
propshaft shield.

2. Add the recommended lubricant as
needed to maintain the oil level at
the bottom of the fill hole threads.

3. Reinstall the fill plug.

Transmission Oil Change

1. Remove the propshaft shield from t he right side of the vehicle to
access the fill plug. Remove the fill plug.

2. Remove the transmission drain plug located on the bottom
left-hand side and drain the oil into an appropriate container.
Discard used oil properly.

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

4. Add the proper amount of the recommended lubricant. Refer to the
specifications section beginning on page 114 for capacities.

5. Reinstall the fill plug and check for leaks.

6. Reinstall the propshaft shield.

1

83

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Front Gearcase Oil Check

The front gearcase oil level should be checked every six months or
1000 miles (1600 km), whichever comes first. Maintain the oil level at
the bottom of the fill plug threads. Change the oil annually. We
recommend the use of Polaris Angle
Drive Fluid. See page 117 for the part
numbers of Polaris products.

1. Position the ATV on a level
surface.

2. Remove the fill plug (1) and check
the oil level.

3. Add the recommended oil as
needed to maintain the level at the
bottom of the fill plug threads.

4. Reinstall the fill plug.

Front Gearcase Oil Change

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

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

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

4. Add 4 oz. (120 ml) of the recommended gearcase oil.

5. Reinstall the fill plug and check for leaks.

1

84

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Drive Chain

Polaris ATV drive chains are equipped with o-ring-sealed, permanently
greased pins and rollers. However, the outer surfaces of the roller must
be lubricated.

Always inspect the drive chain prior to operating the vehicle. Check for
damaged or missing o-rings or damaged rollers. Also check for correct
slack adjustment. Maintain the stone guard to rear sprocket clearance
at 1/8″ (.3 cm).

Regularly lubricate the drive chain with Polaris Chain Lube, an SAE
80-90 lube or an approved o-ring chain spray lube. See page 117 for the
part numbers of Polaris products.

Washing the drive chain with a high pressure washer or gasoline
can cause damage to the o-rings, causing premature wear and
drive chain failure. Do not use a high pressure washer or
gasoline to clean the drive chain.

CAUTION

85

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 the 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 P olaris 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.

1

2

3

86

MAINTENANCE AND LUBRICATION

Adjustments

Brakes

The front and rear brakes are hydraulic disc brakes, activated by
moving the single brake lever toward 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, such as in hilly country or in muddy terrain.

1. Always maintain brake fluid at an adequate level (see page 41).

NOTE: Under normal operation, the diaphragm extends into the
reservoir as fluid level drops. If the fluid level is low and the
diaphragm is not extended, a leak is likely and the diaphragm should
be replaced. Always fill the reservoir as needed whenever the cover is
loosened or removed to ensure proper diaphragm operation. Use
Polaris DOT 3 brake fluid. Do not overfill.

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

WARNING

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

WARNING

87

MAINTENANCE AND LUBRICATION

Adjustments

Brakes

1. Check the brake system for fluid leaks.

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

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

4. 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.

Auxiliary Brake

The 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 requires no adjustment.

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

3/64″ (.1 cm)

88

MAINTENANCE AND LUBRICATION

Adjustments

Steering Assembly

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

Camber and Caster

The camber and caster are non-adjustable.

Rear Spring

The rear shock absorber spring is
adjusted by rotating the adjuster (1)
either clockwise or counterclockwise
to increase or decrease spring
tension.

NOTE: Accessory springs are
available through your Polaris dealer.

Throttle Cable Freeplay

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 . NOTE: While adjusting freeplay, be sure to flip the

throttle lever back and forth.

3. Tighten the locknut and slide the boots over the cable adjuster until

they touch at the midpoint of the adjuster.

1

1

2

1

3

89

MAINTENANCE AND LUBRICATION

Adjustments

Handlebars

The handlebars can be adjusted for
rider preference.

1. Remove the handlebar cover to
access the handlebar bolts (1).

2. Loosen the four bolts.

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

4. Torque the two front bolts to 10-12 ft. lbs. (14-17 Nm), then
torque the two rear bolts. A gap of up to 1/8” will remain at the
rear bolts.

Improper adjustment of the handlebars or incorrect torquing of
the adjuster block tightening bolts can cause limited steering or
loosening of the handlebars, resulting in loss of control and
possible serious personal injury or death. Follow the adjustment
procedures exactly, or see your Polaris dealer for service.

WARNING

1

90

MAINTENANCE AND LUBRICATION

Adjustments

Carburetor

IMPORTANT: Your Polaris ATV is calibrated at the factory for
optimal performance at altitudes ranging from zero t o 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 to 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 and engine or
PVT damage. See your Polaris dealer for more information about
jetting the ATV for conditions in your area.

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

1. Warm up the engine by running the
vehicle for approximately five minutes.

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

3. Adjust the carburetor idle screw (1) either
in or out until the desired idle RPM is
reached. Refer to the specifications
section beginning on page 114 for the
proper setting.
NOTE: Turn the screw in (clockwise) t o
raise RPM. Turn the screw out
(counterclockwise) to lower RPM.

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MAINTENANCE AND LUBRICATION

Adjustments

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

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

Always use original equipment size and type when
replacing tires.

Make sure the wheels are installed properly.

Always replace tires when the tread depth measures 1/8″
(.3 cm) or less.

WARNING

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MAINTENANCE AND LUBRICATION

Adjustments

Wheel Installation

1. Make sure the transmission is in
gear with the parking brake
locked.

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

3. Install the wheel nuts and finger
tighten.

4. Lower the vehicle to the ground.

5. Torque the wheel nuts according to the wheel nut torque
specifications chart.

NOTE: All nuts that have a cotter pin installed must be serviced by an
authorized Polaris dealer.

Wheel Nut Torque Specifications

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

Bolt Size Specification

Front 3/8″ 20 ft. lbs. (27 Nm)

Rear 3/8″ 20 ft. lbs. (27 Nm)

Rear 1/2″ 50 ft. lbs. (68 Nm)

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MAINTENANCE AND LUBRICATION

Adjustments

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.

Tire Tread Depth

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

1/8I (.3 cm)

WARNING

Operating the vehicle with worn tires will increase the
possibility of skidding, which could lead to loss of control and
serious injury or death. Always replace tires when the tread
depth measures 1/8″ (.3 cm) or less.

Use of non-standard size or type of tires or improper tire
inflation may adversely affect vehicle maneuverability and cause
loss of control resulting in serious injury or death. Maintain
proper tire pressure as outlined in this owner’s manual. When
replacing a tire always use original equipment size and type.

WARNING

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MAINTENANCE AND LUBRICATION

Adjustments

Rear Drive Chain Slack

Check the amount of chain slack in three different locations by moving
the vehicle slightly forward to gain slack at the top side of the rear
chain. Measure the chain slack at the tightest of the three positions. At
this point the chain should have 3/16″-3/8″ (.48 cm - .95 cm)
deflection. Use the following procedure if adjustment is required.

1. Remove the chain guard if

applicable.

2. Loosen the chain guide.

3. Loosen the two eccentric

locking bolts (1).

4. Loosen the caliper mounting

bracket bolt located on the
side of the swing arm.

5. Insert a pin punch (2) through the sprocket hub and into the

eccentric housing.

Adjusting or operating the ATV with improper rear drive chain
slack can result in severe damage to the transmission and drive
components. Always make sure the slack is within the stated
specifications.

CAUTION

3/16″-3/8″ (.48 cm - .95 cm)

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2

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MAINTENANCE AND LUBRICATION

Adjustments

Rear Drive Chain Slack

6. Roll the ATV forward or backward
to adjust the chain slack to the
proper tension. See the illustration
for proper splice link clip opening
position (1).

7. Tighten the eccentric locking bolts
to 30 ft. lbs. (41 Nm) for machines
without the hitch and 45 ft. lbs. (61
Nm) for machines with a hitch.

8. Tighten the caliper mount bolt to 10-12 ft. lbs. (14-17 Nm)

9. Remove the pin punch.

10. Roll the ATV forward, checking chain tension in several places
around the chain. NOTE: The chain is adjusted correctly when the
tightest portion of the chain has approximately 3/8” (10mm)
deflection.

11. Position the chain guide to allow 1/8” (3mm) clearance and tighten
the retaining bolt to 5 ft. lbs. (7 Nm).

12. Reinstall the chain guard if applicable.

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MAINTENANCE AND LUBRICATION

Engine Cooling System

Coolant Level

The recovery bottle (1) is located
on the left side of the machine.
The fluid level must be maintained
between the minimum and
maximum marks on the bottle
(when the fluid is cool).

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

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

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

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. See page 117 for the
part numbers of Polaris products.

NOTE: Polaris Premium 60/40 is already premixed and ready to use.
Do not dilute with water.

NOTE: Always follow the manufacturer’s mixing recommendations
for the freeze protection required in your area.

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MAINTENANCE AND LUBRICATION

Engine Cooling System

Radiator Coolant Level

NOTE: This procedure is required only
if the cooling system has been drained
for maintenance and/or repair. However,
if the recovery bottle has run dry, the
level in t he radiator should be inspected
and coolant added if necessary.

1. Remove the front panel to access the
radiator pressure cap (1). Remove
the cap.

2. If coolant is low, use a funnel and
slowly add coolant through the
radiator filler neck.

3. Reinstall the pressure cap and secure the front panel.

4. Fill the coolant recovery bottle to the upper mark on the bottle.

5. Check the coolant level in the bottle frequently, adding coolant as
needed until the level stabilizes.

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

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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