Thank you for purchasing a Polaris vehicle, and welcome to our
world-wide family of Polaris owners. We proudly produce an exciting
line of utility and recreational products.
S Snowmobiles
S All-terrain vehicles (ATVs)
S Quadricycles
S RANGER utility vehicles
S Victory motorcycles
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 complete line of apparel, parts and
accessories, available through our online store at
www.purepolaris.com. Have your accessories and clothing delivered
right to your door!
1
Copyright 2007 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.
2008 Scrambler 500 2X4 International Owner’s Manual P/N 9921620
Printed in U.S.A.
2
TABLE OF CONTENTS
Know Your Vehicle5.........................
Safety6.....................................
Features and Controls31.....................
Operation41.................................
Emission Control Systems59.................
Maintenance60..............................
Specifications108............................
Polaris Products111.........................
T roubleshooting1 12.........................
Warranty116................................
Maintenance Log1 18.........................
Index121....................................
3
4
KNOW YOUR VEHICLE
As the operator of the vehicle, you are responsible for your personal
safety, the safety of others, and the protection of our environment.
Read and understand your owner’s manual, which includes valuable
information about all aspects of your vehicle, including safe operating
procedures.
Ride responsibly. Know all laws and regulations concerning the
operation of this vehicle in your area.
Vehicle Identification Numbers
Record your vehicle’s identification numbers and key number in the
spaces provided. Remove the spare key and store it in a safe place. An
ignition key can be duplicated only by ordering a Polaris key blank
(using your key number) and mating it with one of your existing keys.
The ignition switch must be replaced if all keys are lost.
31XX
1
Vehicle Model Number:
Frame VIN (1):
Engine Serial Number (right front side of engine crankcase):
Key Number (2):
2
5
SAFETY
Operator Safety
The following signal words and symbols appear throughout this
manual and on your vehicle. Your safety is involved when these words
and symbols are used. Become familiar with their meanings before
reading the manual.
The safety alert symbol, on your vehicle or in this manual, alerts
you to the potential for personal injury.
WARNING
The safety alert warning indicates a potential hazard that may
result in serious injury or death.
CAUTION
The safety alert caution indicates a potential hazard that may
result in minor personal injury or damage to the vehicle.
CAUTION
A caution indicates a situation that may result in damage to the
vehicle.
NOTE:
A note will alert you to important information or instructions.
6
SAFETY
Operator Safety
WARNING
Failure to follow the warnings contained in this manual can result
in serious injury or death. A Polaris Quadricycle 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 Quadricycle.
Safety Training
When you purchased your new Quadricycle, your dealer offered a
hands-on safety training course. You were also provided with printed
materials that explain safe operating procedures. Review this
information on a regular basis.
If you purchased a used Polaris Quadricycle from a party other than a
Polaris dealer, please request free safety training from any authorized
Polaris dealer.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age.
Equipment Modifications
The warranty on your Polaris Quadricycle 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.
7
SAFETY
Operator Safety
WARNING
Serious injury or death can result if you do not follow these
instructions and procedures, which are outlined in further detail
within your owner’s manual.
S Read this manual and all labels carefully, and follow the operating
procedures described.
S Never operate a Quadricycle without proper instruction. Tak e a
training course. Beginners should receive training from a certified
instructor. Contact an authorized Polaris Quadricycle dealer or visit
the Polaris web site at www.polarisindustries.com.
S Never allow anyone under 16 years of age to operate this Quadri-
cycle.
S Never permit a guest to operate the Quadricycle unless t he guest has
read this manual and all product labels and has completed a certified
safety training course.
S Never operate a Quadricycle 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 a Quadri-
cycle.
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 Quadricycle before each use to make sure it’s in
safe operating condition. Always follow t he 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 Quadricycle during operation.
S Always travel slowly and use extra caution when operating on unfa-
miliar terrain. Be alert to changing terrain conditions.
S Never operate on excessively rough, slippery, or loose terrain.
S Always follow proper turning procedures as described in this manu-
al. Practice turning at low speeds before attempting to turn at faster
speeds. Do not turn at excessive speeds.
8
SAFETY
Operator Safety
S Always have the Quadricycle inspected by an authorized Polaris
dealer if it’s been involved in an accident.
S Never operate on hills too steep for the Quadricycle or for your abili-
ties. 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 Quadricycle. Never attempt to turn
the Quadricycle around on any hill until you’ve mastered (on level
ground) the turning technique outlined in this manual. Avoid crossing the side of a steep hill when possible.
S Always use proper procedures if you stall or roll backwards while
climbing a hill. To avoid stalling, maintain a steady speed when
climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Always dismount on the
uphill side, or to either side if the Quadricycle is pointed straight
uphill. Turn the Quadricycle 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 Quadricycle 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.
9
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 vehicle before oper-
ating in reverse. When it’ s safe to proceed in reverse, move slowly
and avoid turning at sharp angles.
S Always use the size and type of tires specified for your vehicle, and
always maintain proper tire pressure.
S Never modify a Quadricycle through improper installation or use of
accessories.
S Never exceed the stated load capacity for your vehicle. Cargo must
be properly distributed and securely attached. Reduce speed and
follow the instructions in this manual for 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 QUADRICYCLE SAFETY,
contact an authorized Polaris Quadricycle dealer or visit the
Polaris web site at www.polarisindustries.com.
10
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this Quadricycle without proper instruction.
WHAT CAN
The risk of an accident is greatly increased if the operator does
not know how to operate the Quadricycle properly in different
situations and on different types of terrain.
HOW TO AVOID THE
Never operate a Quadricycle without proper instruction. Take a
training course. Beginners should receive training from a certified
instructor. Contact an authorized Polaris Quadricycle dealer or
visit the Polaris web site at www.polarisindustries.com.
HAPPEN
HAZARD
WARNING
POTENTIAL HAZARD
Failure to follow the age recommendations for this Quadricycle.
WHAT CAN
Severe injury and/or death could occur if a child under the
minimum age recommendation operates a Quadricycle.
Even though a child may be within the recommended age group
for operating some Quadricycles, he/she may not have the skills,
abilities, or judgment needed to operate a Quadricycle safely and
could be susceptible to accident or injury.
HOW TO AVOID THE
Never allow anyone under 16 years of age to operate this vehicle.
HAPPEN
HAZARD
11
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Carrying a passenger on a
Quadricycle.
WHAT CAN
Carrying a passenger
greatly reduces the
operator’s ability to balance
and control the Quadricycle,
which could cause an
accident and injury to
the operator and/or
passenger.
HOW TO AVOID THE
Never carry a passenger. The purpose of the long seat is to
allow the operator to shift position as needed during operation. It
is not intended for carrying passengers.
HAPPEN
HAZARD
12
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this Quadricycle
without wearing an
approved helmet, eye
protection and protective
clothing.
WHAT CAN
Operating a Quadricycle
without an approved
helmet increases the risk
of a severe head injury or
death in the event of an
accident.
Operating without eye protection could result in an accident and
could increase the chance of a severe injury in the event of an
accident.
HOW TO AVOID THE
Always wear an approved helmet that fits properly.
Always wear eye protection (goggles or face shield), gloves,
boots, long-sleeved shirt or jacket, and long pants.
HAPPEN
HAZARD
SAFETY
13
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating the Quadricycle after
consuming alcohol or drugs.
WHAT CAN
Consumption of alcohol and/or drugs
could seriously affect operator
judgment. Reaction time may be slower
and operator balance and perception
could be affected.
Consuming alcohol and/or drugs before
or while operating a Quadricycle could
result in an accident causing severe injury or death.
HOW TO AVOID THE
Never consume alcohol or drugs before or while operating a
Quadricycle.
HAPPEN
HAZARD
WARNING
POTENTIAL HAZARD
Operating the Quadricycle at excessive speeds.
WHAT CAN
Excessive speed increases the operator’s chance of losing
control of the Quadricycle, which can result in an accident.
HOW TO AVOID THE
Always operate the Quadricycle at a speed that’s proper for the
terrain, visibility and operating conditions, and your experience.
HAPPEN
HAZARD
14
Operator Safety
WARNING
POTENTIAL HAZARD
Attempting wheelies, jumps
and other stunts.
WHAT CAN
Attempting stunts increases
the chance of an accident,
including an overturn.
HOW TO AVOID
HAZARD
Never attempt wheelies,
jumps, or other stunts. Avoid
exhibition driving.
HAPPEN
THE
WARNING
POTENTIAL HAZARD
Failure to inspect the Quadricycle before operating.
Failure to properly maintain the Quadricycle.
WHAT CAN
Poor maintenance increases the possibility of an accident or
equipment damage.
HOW TO AVOID THE
Always inspect your Quadricycle before each use to make sure
it’s in safe operating condition.
Always follow the inspection and maintenance procedures and
schedules described in the owner’s manual.
HAPPEN
HAZARD
SAFETY
15
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Removing hands from the handlebars or feet from the footrests
during operation.
WHAT CAN
Removing even one hand or foot can reduce ability to control the
vehicle or could cause loss of balance and ejection from the
Quadricycle.
If the operator’s foot is not firmly planted on the footrest, it could
come into contact with the rear wheels and lead to accident or
injury.
HOW TO AVOID THE
Always keep both hands on the handlebars and both feet on the
footrests of the Quadricycle during operation.
HAPPEN
HAZARD
WARNING
POTENTIAL HAZARD
Failure to use extra
caution when operating
the Quadricycle on
unfamiliar terrain.
WHAT CAN
Unfamiliar terrain may
contain hidden rocks,
bumps, or holes that could
cause loss of control or
overturn.
HOW TO AVOID THE
Travel slowly and use extra caution when operating on unfamiliar
terrain. Always be alert to changing terrain conditions.
HAPPEN
HAZARD
16
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Failure to use extra
caution when operating on
excessively rough,
slippery or loose terrain.
WHAT CAN
Operating on excessively
rough, slippery or loose
terrain could cause loss of
traction or loss of control,
which could result in an
accident or overturn.
HOW TO AVOID THE
Do not operate on excessively rough, slippery or loose terrain
until you’ve learned and practiced the skills necessary to control
the Quadricycle on such terrain.
Always use extra caution on rough, slippery or loose terrain.
HAPPEN
HAZARD
WARNING
POTENTIAL HAZARD
Turning improperly.
WHAT CAN
Improper turns could cause loss of control and lead to a collision
or overturn.
HOW TO AVOID THE
Always follow proper procedures for turning as described in the
owner’s manual.
Practice turning at slow speeds before attempting to turn at faster
speeds.
Never turn at excessive speed.
HAPPEN
HAZARD
17
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating on excessively steep hills.
WHAT CAN
The vehicle may overturn.
HOW TO AVOID THE
Never operate on hills too steep for the Quadricycle or for your
abilities. Never operate the Quadricycle on hills steeper than
25_.
Practice on smaller hills before attempting large hills.
HAPPEN
HAZARD
WARNING
POTENTIAL HAZARD
Climbing hills improperly.
WHAT CAN
Improper hill climbing could
cause loss of control or
overturn.
HOW TO AVOID
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 Quadricycle 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
vehicle could flip over backwards.
Never go over the top of any hill at high speed. An obstacle, a
sharp drop, or another vehicle or person could be on the other
side of the hill.
HAPPEN
THE
18
Operator Safety
WARNING
POTENTIAL HAZARD
Traveling downhill
improperly.
WHAT CAN
Improperly descending a hill
could cause loss of control
or overturn.
HOW TO AVOID
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 53.
Always check the terrain carefully before descending a hill.
Shift your weight backward.
Never travel down a hill at high speed.
Avoid traveling down a hill at an angle, which would cause the
vehicle to lean sharply to one side. Travel straight down the hill
when possible.
HAPPEN
THE
SAFETY
19
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Improperly crossing hills and
turning on hills.
WHAT CAN
Improperly crossing or
turning as hills could cause
loss of control or overturn.
HOW TO AVOID
HAZARD
Neverattempttoturnthe
Quadricycle around on any
hill until you’ve mastered the
turning technique (on level
ground) as described in the
owner’s manual. See page
54. Use extra caution when
turning on any hill.
Avoid crossing the side of a steep hill.
When crossing the side of a
Always follow proper procedures as described in the owner’s
manual.
Avoid hills with excessively slippery or loose surfaces.
Shift your weight to the uphill side of the Quadricycle.
HAPPEN
THE
hill:
20
Operator Safety
WARNING
POTENTIAL HAZARD
Stalling, rolling backwards
or improperly dismounting
while climbing a hill.
WHAT CAN
The vehicle could overturn.
HOW TO AVOID
HAZARD
Maintain steady speed
when climbing a hill.
If all forward speed is
Keep your weight uphill.
Apply the single lever brake gradually.
When fully stopped, apply the auxiliary rear brake as well, then
lock the parking brake.
If the Quadricycle begins rolling
Keep weight uphill.
Never apply engine power.
Never apply the auxiliary rear brake while rolling backwards.
Apply the single-lever brake gradually.
When fully stopped, apply the auxiliary rear brake as well, and
then lock the parking brake.
Dismount on uphill side, or to either side if vehicle is pointed
straight uphill.
Turn the vehicle around and remount, following the procedure
described in the owner’s manual. See page 54.
HAPPEN
THE
lost:
backwards:
SAFETY
21
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Improperly operating over obstacles.
WHAT CAN
Operating over obstacles could cause loss of control or overturn.
HOW TO AVOID THE
Before operating in a new area, check for obstacles.
Avoid operating over large obstacles such as rocks and fallen
trees when possible. If unavoidable, use extreme caution and
always follow proper procedures as outlined in the owner’s
manual.
HAPPEN
HAZARD
WARNING
POTENTIAL HAZARD
Skidding or sliding.
WHAT CAN
Skidding or sliding can cause loss of control.
If the tires regain traction unexpectedly, the vehicle could
overturn.
HOW TO AVOID THE
On slippery surfaces such as ice, travel slowly and use extra
caution to reduce the chance of skidding or sliding out of control.
HAPPEN
HAZARD
WARNING
POTENTIAL HAZARD
Improperly operating in reverse.
WHAT CAN
The Quadricycle could collide with an obstacle or person,
resulting in severe injury.
HOW TO AVOID THE
Before shifting into reverse gear, always check for obstacles or
people behind the vehicle. When it’s safe to proceed, back
slowly.
22
HAPPEN
HAZARD
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating the Quadricycle through deep or fast-flowing water.
WHAT CAN
Tires may float, causing loss of traction and loss of control, which
could lead to an accident or overturn.
HOW TO AVOID THE
Avoid operating the Quadricycle through deep or fast-flowing
water. If it’s unavoidable to enter water that exceeds the
recommended maximum depth (see page 55), travel slowly,
balance your weight carefully, avoid sudden movements, and
maintain a slow and steady forward motion. Do not make sudden
turns or stops, and do not make sudden throttle changes.
Wet brakes may have reduced stopping ability. Always test the
brakes after leaving water. If necessary, apply them several
times to let friction dry out the pads.
HAPPEN
HAZARD
WARNING
POTENTIAL HAZARD
Operating this Quadricycle with improper tires, or with improper
or uneven tire pressure.
WHAT CAN
Use of improper tires, or operation of the Quadricycle with
improper or uneven tire pressure, could cause loss of control or
accident.
HOW TO AVOID THE
Always use the size and type of tires specified for the vehicle.
Always maintain proper tire pressure as specified.
HAPPEN
HAZARD
23
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating the Quadricycle with improper modifications.
WHAT CAN
Improper installation of accessories or modification of the
Quadricycle may cause changes in handling which could lead to
an accident.
HOW TO AVOID THE
Never modify the Quadricycle 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 Quadricycle and should be installed and
used according to approved instructions. See your authorized
Polaris Quadricycle dealer for more information.
HAPPEN
HAZARD
WARNING
POTENTIAL HAZARD
Overloading the Quadricycle or carrying/towing cargo improperly.
WHAT CAN
Overloading and towing can cause changes in vehicle handling,
which could lead to loss of control or an accident.
HOW TO AVOID THE
Never exceed the stated load capacity for this vehicle.
Cargo should be properly distributed and securely attached.
Reduce speed when carrying cargo or pulling a trailer. Allow a
greater distance for braking.
Always follow the instructions in the owner’s manual for carrying
cargo or pulling a trailer. See page 46.
HAPPEN
HAZARD
WARNING
POTENTIAL HAZARD
Operating on frozen bodies of water.
WHAT CAN
Severe injury or death can result if the vehicle and/or the operator
fall through the ice.
HOW TO AVOID THE
Never operate the Quadricycle on a frozen body of water.
24
HAPPEN
HAZARD
SAFETY
Operator Safety
WARNING
Leaving the keys in the ignition can lead to unauthorized use of
the vehicle resulting in serious injury or death. Always remove
the ignition key when the vehicle is not in use.
WARNING
After any overturn or accident, have a qualified service dealer
inspect the entire vehicle for possible damage, including (but not
limited to) brakes, throttle and steering systems.
WARNING
Safe operation of this rider-active vehicle requires good
judgement and physical skills. Persons with cognitive or physical
disabilities who operate this vehicle have an increased risk of
overturn and loss of control, which could result in severe injury or
death.
CAUTION
Exhaust system components are very hot during and after use of
the vehicle. Hot components can cause serious burns and fire.
Do not touch hot exhaust system components. Always keep
combustible materials away from the exhaust system. Use
caution when traveling through tall grass, especially dry grass.
25
SAFETY
Fuel Safety
WARNING
Gasoline is highly flammable and explosive under certain
conditions.
S Always exercise extreme caution whenever handling gasoline.
S Always refuel with the engine stopped, and outdoors or in a well
ventilated area.
S Do not smoke or allow open flames or sparks in or near the
area where refueling is performed or where gasoline is stored.
S Do not overfill the tank. Do not fill the tank neck.
S If gasoline spills on your skin or clothing, immediately wash it off
with soap and water and change clothing.
S Never start the engine or let it run in an enclosed area.
Engine exhaust fumes are poisonous and can cause loss of
consciousness or death in a short time.
S Turn the fuel valve off whenever the vehicle is stored or parked.
WARNING
The engine exhaust from this product contains chemicals known
to cause cancer, birth defects or other reproductive harm.
Operate this vehicle only outdoors or in well-ventilated areas.
26
1
SAFETY
Safety Decals and Locations
Warning decals have been placed on the vehicle for your protection.
Read and follow the instructions of the decals on the vehicle carefully.
If any of the decals depicted in this manual differ from the decals on
your vehicle, always read and follow the instructions of the decals onthe vehicle.
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.
Discretionary Warning (1)
WARNING
S Never operate this vehicle on
HILLS steeper than 25 degrees
25°. To prevent flipover on
hilly terrain, when going up or
down, use throttle and brakes
gradually.
S REVERSE operation can be
dangerous, even at low speeds.
Steering becomes difficult. To
prevent flipover, avoid sudden
braking or sharp turns.
S Use OVERRIDE for reverse
speed limiter with caution. To
prevent loss of control, never activate
override button with open throttle.
S PARKING BRAKE may relax when used
for more than 5 minutes. When parking on grades, leave shift in forward.
2
Clutch Cover Warning (2)
WARNING
NO STEP
S Moving parts hazard under belt-clutch guard. To prevent serious injury, do
not operate vehicle with guard removed.
S Do not modify engine or clutch. Doing so can cause part failure, possible im-
balance, and excessive engine RPM, which can result in serious injury or
death.
27
SAFETY
Safety Decals and Locations
General Warning (3)
WARNING
Improper ATV use can result in
SEVERE INJURY or DEATH
ALWAYS USE AN APPROVED
HELMET AND PROTECTIVE GEAR
NEVER USE ON PUBLIC ROADS
NEVER CARRY PASSENGERS
NEVER USE WITH DRUGS OR
ALCOHOL
NEVER operate:
S without proper training or instruction
S at speeds too fast for your skills or the
conditions
S on public roads -- a collision can occur with
another vehicle
S with a passenger -- passengers affect balance and steering and increase risk
of losing control
ALWAYS:
S use proper riding techniques to avoid vehicle overturns on hills and rough
terrain and in turns
S avoid paved surfaces -- pavement may seriously affect handling and control
LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS
AND WARNINGS. IF OWNER’S MANUAL IS MISSING, CONTACT A POLARIS
DEALER FOR A REPLACEMENT.
3
28
SAFETY
Safety Decals and Locations
No Passenger Warning (4)
WARNING
NEVER ride as a passenger.
Passengers can cause a
loss of control, resulting in
SEVERE INJURY or
DEATH.
Age16Warning(5)
WARNING
Operating this ATV if you
are under the age of 16
increases your chance of
severe injury or death. NEVER
operate this ATV if you are under age 16.
Tire Pressure/Load Warning (6)
WARNING
IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control
resulting in SEVERE INJURY OR DEATH.
TIRE PRESSURE IN PSI (KPa): FRONT 4 (27.6) REAR 3 (20.7)
MAXIMUM WEIGHT CAPACITY 305 LBS. (138 kg).
INCLUDES WEIGHT OF OPERATOR, CARGO AND ACCESSORIES
Reduce speed and allow greater distance for braking when carrying cargo.
Overloading or carrying tall, off-center, or unsecured loads will increase your
risk of losing control. Loads should be centered, carried as low as possible, and
firmly secured to the racks. With dual racks, load distribution 1/3 front 2/3 rear is
best. For stability on rough or hilly terrain, reduce speed and cargo. Do not
block headlight. Be careful if load extends over the side of the rack.
Read Owner’s Manual for more detailed loading information.
5
4
6
29
SAFETY
Safe Riding Gear
Always wear clothing suited to the type of riding. Quadricycle riding
requires special protective clothing for comfort and to reduce the
chance of injury.
1. Helmet
Wearing a helmet can prevent a severe head
injury. Whenever riding a Polaris vehicle,
always wear a helmet that meets or exceeds
established safety standards.
Approved helmets in the USA and Canada
bear a U.S. Department of Transportation
(DOT) label.
Approved helmets in Europe, Asia and
Oceania bear the ECE 22.05 label.
The ECE mark consists of
a circle surrounding the
letter E, followed by the
distinguishing number of
the country which has
granted approval. The
approval number and serial
number will also be
displayed on the label.
4
E
051039
0006.031
2. Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection.
Whenever riding a Polaris vehicle, always wear shatterproof goggles or
use a shatterproof helmet face shield. Polaris recommends wearing
approved Personal Protective Equipment (PPE) bearing markings such
as VESC 8, V--8, Z87.1, or CE. Make sure protective eye wear is kept
clean.
3. Glo ves
Off-road style gloves with knuckle pads are the best for comfort and
protection.
4. Boots
The best footwear is a pair of sturdy over-the-calf boots with low heels.
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
5
4
30
FEATURES AND CONTROLS
Electrical Switches
3
1
2
WARNING
Activating the override switch while the throttle is open can cause
loss of control, resulting in severe injury or death. Do not activate
the override switch while the throttle is open.
Override Switch (1) (Reverse Speed Limiter) This vehicle is equipped with a reverse speed limiter
system. To gain additional power while backing,
depress the override switch.
Main Switch (2) - To start the engine, slide the stop switch to the
center RUN position and turn the main key switch clockwise past the
ON position. Release the key when the engine starts.
NOTE:Turn off the main switch to end all electrical power to the
vehicle, including the lights.
RUN OFFOFF
3
WARNING
Leaving the keys in the ignition can lead to unauthorized use of
the vehicle resulting in serious injury or death. Always remove
the ignition key when the vehicle is not in use.
Engine Stop Switch (3) - The engine will not start or run when the
switch 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.
31
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.
1
Indicator Lights
With the engine running, verify the function of all indicator lights each
time the vehicle is used.
NOTE:The taillight is on whenever the main switch (key) is on. Turn
3
1. Transmission Neutral Indicator
2. Transmission Reverse In dicator
3. HighTempWarning(displays if engine overheats)
the key off to prevent battery drain.
1
2
32
FEATURES AND CONTROLS
Throttle Lever
WARNING
Do not start or operate a Quadricycle 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.
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 vehicle is equipped with
Polaris Electronic Throttle Control
(ETC), which is designed to reduce the risk of a frozen or stuck
throttle. If the throttle cable should stick in an open position when the
operator releases the throttle lever, the engine will stop, and power to
the rear wheels will cease.
1
WARNING
The Electronic Throttle Control (ETC) stops the engine in the
event of a throttle system malfunction and is provided f or your
safety. Do not attempt to modify the ETC system or replace it
with any after market throttle mechanisms.
33
FEATURES AND CONTROLS
Brake Lever
WARNING
Operating the vehicle with a spongy brake lever can result in loss
of braking, which could cause an accident. Never operate the
vehicle with a spongy-feeling 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.
1
34
FEATURES AND CONTROLS
Brakes
Check the brake fluid level in the
master cylinder before each use of
the vehicle. 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.
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.
1
2
NOTE:When checking the fluid level, the vehicle must be on level
ground with the handlebars straight. If the fluid level is low
add DOT 4 brake fluid only. DO NOT OVERFILL. See page
1 11 for the part numbers of Polaris products.
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.
35
FEATURES AND CONTROLS
Parking Brake
WARNING
Operating the vehicle while the parking brake is engaged could
result in an accident and serious injury or death. Always check to
be sure the parking brake is disengaged before operating.
Locking the Parking Brake
1. Squeeze and release the brake lever two or
three times, then squeeze and hold.
2. Push the parking brake lock (1)
forward to engage the brake.
Release the brake lever.
3. To release t he parking brake lock,
squeeze and release the brake
lever. It will return to its unlocked
position.
Important Safeguards
S The parking brake may relax if left on for a long period of time. Al-
ways block the wheels to prevent rolling.
S Always block the wheels on the downhill side of the vehicle if leav-
ing it parked on a hill. Another option is to park the vehicle in a
sidehill position.
S Never depend on the parking brake alone if the vehicle is parked on
a hill. Always block the wheels to prevent rolling.
1
36
FEATURES AND CONTROLS
Auxiliary Brake
WARNING
Aggressively applying the 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.
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 m aximum and minimum marks.
1
37
FEATURES AND CONTROLS
Choke
The choke assists in starting a cold engine. Refer to the engine starting
procedure on page 43 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 main
supply is exhausted.
NOTE:There’s about a 7 to 10 mile
(11.2 to 16 km) range on
reserve gas. Always refill the
gas tank as soon as possible
after using the reserve supply.
Always return the valve to the ON
position after refueling.
2
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.
1
38
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
F
N
R
1
CAUTION
Shifting gears with the engine speed above idle or while the
vehicle is moving could cause transmission damage.
To change gears, stop the vehicle, and with the engine idling,
move the lever to the desired gear.
Whenever the vehicle is left unattended, always place the transmission
in gear and lock the parking brake.
39
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 36).
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 43.
4. Grasp the recoil starter rope handle (2) firmly and pull slowly so
you can feel the engine strokes.
2
1
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.
CAUTION
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.
40
OPERATION
Break-In Period
The break-in period for your new Polaris Quadricycle is 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 and drive components will result in more efficient performance
and longer life for these components.
CAUTION
Excessive heat build-up during the first three hours of operation
will damage close-fitted engine parts and drive components. Do
not operate at full throttle or high speeds during the first three
hours of use.
Engine an d Drivetrain Break-in
1. Fill the fuel tank with
gasoline (see page 38).
2. Check the oil level on
the dipstick (see page
66). 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 42.
6. Pull only light loads.
7. During the break-in period, change both the oil and the filter at 25
hours or one month, whichever comes first.
ADD 8 OZ.NORMALFULL
1
PVT Break-in (Clutches/Belt)
A proper break-in of the clutches and drive belt will ensure a longer
life and better performance. Break in the clutches and belt by
operating at slower speeds during the break-in period as recommended.
Pull only light loads. Avoid aggressive acceleration and high speed
operation during the break-in period.
41
OPERATION
Pre-Ride Inspection
WARNING
If a proper inspection is not done before each use, severe injury
or death could result. Always inspect the vehicle before each use
to ensure it’s in proper operating condition.
Pre-Ride Checklist
ItemRemarksSee
Page
Brake system / lever travelEnsure proper operation34, 74
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.
1. Position the vehicle on a level
surface.
2. Place the transmission in
neutral.
3. Lock the parking brake.
NOTE:The starter interlock will
prevent the engine from
starting if the
transmission is in gear
and the brake is not
engaged.
4. Turn the fuel valve on.
5. Sit on the vehicle.
1
2
NOTE:Do not use the choke if starting a warm engine. Excessive
use of the choke can cause the spark plug to become wet
fouled.
6. If the engine is cold, pull the choke knob out until it stops (1).
NOTE:The variable choke is fully on when the knob is pulled
completely out. The choke is off when the knob is pushed
completely in. The choke can be adjusted gradually,
depending on how much choke is needed for starting. Be
sure the choke is off during operation, as excess fuel
washing into the engine oil will increase wear on engine
components.
NOTE:If the knob doesn’t stay where positioned, increase the
tension by rotating the tension adjusting nut (2) clockwise.
43
OPERATION
Starting the Engine
7. Move the engine stop switch to RUN.
NOTE:Do not press the throttle while starting the engine.
8. 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.
9. If the engine does not start, release the key and wait five seconds.
Activate the starter for another five seconds. Repeat this procedure
until the engine starts.
NOTE:If a warm 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. If the engine is over-choked
when warm, depress the throttle lever fully while cranking to
aid in starting. Release the throttle lever immediately after
the engine starts. If the engine does not start and all
conditions are favorable, change the spark plug and try
again.
10. If the engine slows, position the choke knob half way in to allow
proper engine warm up. Vary the engine RPM slightly with the
throttle to aid in warm-up. When the engine idles smoothly, push
the choke completely in.
CAUTION
Operating the vehicle immediately after starting could cause
engine damage. Allow the engine to warm up for several minutes
before operating the vehicle.
44
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.
45
OPERATION
Driving Safely
Hauling Cargo
2/3
1/3
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°.
46
OPERATION
Driving Safely
Hauling Cargo
WARNING
Hauling cargo improperly can alter vehicle handling and may
cause loss of control or brake instability and result in serious
injury or death. Always follow these precautions when hauling
cargo:
S REDUCE SPEED AND ALLOW GREATER DISTANCE FOR
BRAKING WHEN HAULING CARGO.
S CARGO WEIGHT DISTRIBUTION should be 1/3 on the front
rack and 2/3 on the rear rack. When operating over rough or
hilly terrain, reduce speed and cargo to maintain stable driving
conditions. Carrying loads on one rack only increases the possibility of vehicle overturn.
S LOADS MUST BE CARRIED AS LOW ON THE RACKS AS
POSSIBLE. Carrying loads high on the racks raises the center
of gravity of the vehicle and creates a less stable operating
condition. When cargo loads are carried high on the racks, the
weight of the loads must be reduced to maintain stable operating conditions.
S ALL LOADS MUST BE SECURED BEFORE OPERATING.
Unsecured loads can create unstable operating conditions,
which could result in loss of control of the 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 FASTER THAN THE RECOMMENDED
SPEEDS. Vehicle should never exceed 10 mph (16 kph) while
towing a load on a level grass surface. Vehicle speed should
never exceed 5 mph (8 kph) when towing loads in rough terrain,
while cornering, or while ascending or descending a hill.
47
OPERATION
Driving Safely
Making Turns
Your Polaris vehicle 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.
48
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.
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.
49
OPERATION
Driving Safely
Sidehilling
WARNING
Improperly crossing hills or turning on hills can result in loss of
control or vehicle overturn, resulting in severe injury or death.
Avoid crossing the side of a hill when possible. Follow proper
procedures as outlined in the owner’s manual.
Sidehilling can be a dangerous type of driving and should be avoided if
at all possible. If you do enter into a situation where sidehilling is
necessary, follow these precautions:
1. Slow down.
2. Lean into the hill, 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
50
downhill, if possible, or dismount on the uphill side
immediately!
OPERATION
Driving Safely
Driving Uphill
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.
51
OPERATION
Driving Safely
Driving Uphill
Whenever traveling uphill, follow these precautions:
1. Always travel straight uphill.
2. Avoid steep hills (25_ maximum).
3. Keep both feet on the footrests.
4. Transfer your weight forward.
5. Proceed at a steady rate of speed and throttle opening.
6. Remain alert and be prepared to take emergency action.
This may include quick dismounting of the vehicle.
If all forward speed is lost:
Keep your weight uphill.
Apply the single lever brake, gradually. When fully stopped, apply the
auxiliary brake as well, then lock the parking brake.
If the vehicle 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 vehicle is pointed straight
uphill. Turn the vehicle around and remount, following the procedure
described on page 54.
52
OPERATION
Driving Safely
Driving Downhill
Whenever descending a hill, follow these precautions:
1. Proceed directly downhill.
2. Transfer your weight to the rear of the vehicle.
3. Slow down.
4. Apply the brakes slightly to aid in slowing, using the single brake
lever.
NOTE:Familiarize yourself with operation of the auxiliary rear brake
pedal for additional braking in the event of normal service
brake loss.
WARNING
Excessive speed can cause loss of control and lead to serious
injury or death. Always operate slowly when traveling downhill.
53
OPERATION
Driving Safely
Turning Around on a Hill
If the vehicle stalls while climbing a hill, never back it down the hill!
Use the K-turn to turn around.
8’ (2.4 m)
1. Stop and lock the parking brake while keeping body weight uphill.
2. Leave the transmission in forward and shut off the engine.
3. Dismount on the uphill side of the vehicle, or on the left if the
vehicle is pointing straight uphill.
4. Staying uphill of the vehicle, turn the handlebars full left.
5. While holding the brake lever, release the parking brake lock and
slowly allow the vehicle to roll around to your right until it’s
pointing across the hill or slightly downward.
6. Lock the parking brake 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.
54
OPERATION
Driving Safely
Driving Through Water
Your vehicle 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 60. The following areas
need special attention: engine oil, transmission oil, front and rear
gearcases (if equipped), and all grease fittings.
1
CAUTION
Major engine damage can result if the vehicle is not thoroughly
inspected after operation in water. Perform the services outlined
in the maintenance chart.
If your vehicle becomes immersed or is operated in water that
exceeds the footrest level, take it to your dealer for service before
starting the engine.
NOTE:Avoid operating the vehicle through deep or fast-flowing
water. If you cannot avoid water that exceeds the
recommended maximum depth, go slowly, balance your
weight carefully, avoid sudden 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 91. Have
the vehicle serviced by your dealer at the first opportunity.
55
OPERATION
Driving Safely
Driving Over Obstacles
Be alert! Look ahead and learn to read the terrain you’re traveling on.
Be constantly alert for hazards such as logs, rocks and low hanging
branches.
WARNING
Severe injury or death can result if your vehicle comes in contact
with a hidden obstacle. Not all obstacles are immediately visible.
Travel with caution in unfamiliar terrain.
56
OPERATION
Driving Safely
Driving in Reverse
Follow these precautions
when operating in reverse:
1. Always avoid backing
downhill.
2. Back slowly.
3. When in reverse,
apply the brakes
lightly for stopping.
4. Avoid turning at sharp
angles in reverse.
5. Never open the throttle
suddenly while backing.
WARNING
Failure to use caution when operating in reverse can result in
serious injury or death. Before shifting into reverse, always check
for obstacles or people behind the vehicle. When it’s safe to
proceed, back slowly.
Do not use the override switch unless additional power is required
for vehicle movement. Use with caution.
Avoid backing on inclines, and avoid turning at sharp angles.
NOTE:This Polaris vehicle is 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.
CAUTION
Excessive throttle operation while in the speed limit mode may
cause fuel to build in the exhaust, resulting in engine popping
and/or engine damage.
57
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. Lock the parking brake.
3. Always block the rear wheels on the downhill side. See
illustration.
4. Shut off the fuel supply.
58
EMISSION CONTROL SYSTEMS
Noise Emission Control System
Do not modify the engine, intake or exhaust components, as doing so
may affect compliance with governmental noise level requirements.
Exhaust Emission Control System
The emissions from the exhaust of this vehicle are controlled by engine
design, including factory-set fuel delivery and ignition. The engine
and related components must be maintained at Polaris specifications to
achieve optimal performance.
Engine idle speed is the only adjustment Polaris recommends that the
operator perform. Any other adjustments should be performed by an
authorized Polaris dealer.
Electromagnetic Interference
This spark ignition system complies with USA requirements, Canadian
ICES--002 and European directives 89/336/EEC and 97/24/EC.
59
MAINTENANCE
Periodic Maintenance Chart
Careful periodic maintenance will help keep your vehicle in the safest,
most reliable condition. Inspection, adjustment and lubrication of
important components are explained in the periodic maintenance chart.
Inspect, clean, lubricate, adjust and replace parts as necessary. When
inspection reveals the need for replacement parts, use genuine Polaris
parts available from your Polaris dealer.
Record maintenance and service in the Maintenance Log beginning on
page 118.
NOTE:Service and adjustments are important for proper vehicle
Maintenance intervals in the following chart are based upon average
riding conditions and an average vehicle speed of approximately 10
miles per hour. Vehicles subjected to severe use must be inspected and
serviced more frequently.
Severe Use Definition
S Frequent immersion in mud, water or sand
S Racing or race-style high RPM use
S Prolonged low speed, heavy load operation
S Extended idle
S Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold
weather can indicate contaminants collecting in the oil sump or
crankcase. Change oil immediately if the oil level begins to rise.
Monitor the oil level, and if it continues to rise, discontinue use and
determine the cause or see your dealer.
operation. If you’re not familiar with safe service and
adjustment procedures, have a qualified dealer perform
these operations.
60
MAINTENANCE
j
onpage4
2
Periodic Maintenance Chart
Maintenance Chart Key
"Perform these procedures more frequently for vehicles subjected to
severe use.
EEmission-related service (Failure to conduct this maintenance will
not void the emissions warranty but may affect emissions.)
JHave an authorized Polaris dealer perform these services.
WARNING
Improperly performing the procedures marked with a J could
result in component failure and lead to serious injury or death.
Have an authorized Polaris dealer perform these services.
Perform all services at whichever maintenance interval is reached first.
ItemMaintenance Interval
(whichever comes first)
Hours CalendarMiles
Steering--Pre-Ride--
J
Front suspension--Pre-Ride--
"
Rear suspension--Pre-Ride--
"
Tires--Pre-Ride--
Brake fluid level--Pre-Ride--
"
Brake lever travel--Pre-Ride--
"
Brake system--Pre-Ride--
Wheels/fasteners--Pre-Ride--
Frame fasteners--Pre-Ride--
Engine oil level--Pre-Ride--
"
Air filter, pre-filter--Daily--Inspect; clean often; replace
"
E
Air box sediment
"
tube
Coolant--Daily--Check level daily , change
Headlamp/tail
lamp
Air filter,
"
main element
E
Recoil housing--Weekly--Drain water as needed,
--Daily--Drain deposits when visible
--Daily--Check operation; apply
--Weekly--Inspect; replace as needed
(Km)
Make adjustments as needed. See Pre-Ride Checklist
on page 42.
as needed
coolant every 2 years
dielectric grease if replacing
check often if operating in
wet conditions
Remarks
.
61
MAINTENANCE
Periodic Maintenance Chart
ItemMaintenance Interval
(whichever comes first)
Hours CalendarMiles
Brake pad wear10 HMonthly100 (160)Inspect periodically
"
J
Battery20 HMonthly200 (320)Check terminals; clean; test
Fuel system/filter100 H12 M1000 (1600) Check for leaks at tank cap,
J
E
Radiator
"
(if applicable)
100 H12 M1000 (1600) Inspect; clean external
lines, fuel valve, filter, pump,
carburetor; replace lines
every two years
surfaces
62
Periodic Maintenance Chart
MAINTENANCE
ItemMaintenance Interval
(whichever comes first)
Hours CalendarMiles
Cooling hoses
"
(if applicable)
Engine mounts100 H12 M1000 (1600) Inspect
"
Exhaust muffler/
pipe
Spark plug100 H12 M1000 (1600) Inspect; replace as needed
J
100 H12 M1000 (1600) Inspect for leaks
100 H12 M1000 (1600) Inspect
(Km)
Remarks
E
Ignition T iming100 H12 M1000 (1600) Inspect
J
E
Wiring100 H12 M1000 (1600) Inspect for wear, routing,
"
Clutches (drive
J
and driven)
Front wheel
J
bearings
Brake fluid200 H24 M2000 (3200) Change every two years
J
Spark arrestor300 H36 M3000 (4800) Clean out
Idle speed--Adjust as needed
Toe adjustment--Inspect periodically; adjust
J
Headlight aim--Adjust as needed
100 H12 M1000 (1600) Inspect; clean; replace worn
100 H12 M1000 (1600) Inspect; replace as needed
security; apply dielectric
grease to connectors
subjected to water, mud, etc.
parts
when parts are replaced
" Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service
J Have an authorized Polaris dealer perform these services.
63
MAINTENANCE
Lubrication Recommendations
Always check and change fluids and lubricate greaseable components
at the intervals outlined in the Periodic Maintenance Chart beginning
on page 60. Items not listed in the chart should be lubricated at the
General Lubrication interval.
NOTE:The a-arms and lower control arms are lubricated at the
factory, and no additional lubrication will be needed.
However, if these components are subjected to severe use,
grease zerks have been provided for additional lubrication at
the user’s discretion.
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
FUse Polaris Premium U-Joint Lube every 500 miles, before long
periods of storage, or after pressure washing or s ubmerging
∆When suspension action becomes stiff, or after washing
ItemLubeMethod
Engine OilPS-4 PLUS Performance
BrakesDOT 4 fluid onlyMaintain level between fill lines.
Drive chain(s)O-ring chain lube or SAE
(1) TransmissionAGL Synthetic
(2) Swing Arm Bushings
(3) Tie Rod Ends
(4) Axle Housing
Synthetic 2W-50
80/90
Gearcase Lube
"L Grease
"L∆ Grease
"L Grease
Add to proper level on dipstick.
See page 35.
Lubricate.
Maintain as recommended on
page 70.
Locate fittings on swing arm and
grease with grease gun.
Lift boot, clean away dirt and
grease, apply fresh grease by
hand and reassemble.
Locate fittings on swing arm and
grease with grease gun.
64
Lubrication Recommendations
(1)
(3)
(4)
MAINTENANCE
(2)
65
MAINTENANCE
Engine Oil
Always check and change the engine oil at the intervals outlined in the
Periodic Maintenance Chart beginning on page 60. Always change the
oil filter whenever changing oil.
Oil Recommendations
Polaris recommends the use of Polaris PS-4 PLUS Performance
Synthetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may
need to be changed more frequently if Polaris oil is not used. Always
use 2W-50 oil. Follow the manufacturer’s recommendations for
ambient temperature operation.
See page 111 for the part numbers of Polaris products.
CAUTION
Mixing brands or using a non-recommended oil may cause
serious engine damage. Always use the recommended oil.
Never substitute or mix oil brands.
Oil Ch eck
1. Position the vehicle on a level surface.
2. Start the engine and let it idle for 20-30 seconds. Stop the engine.
3. Remove the dipstick (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.
1
NOTE:The dipstick must be
screwed completely in to
keep the angle and depth
of the stick consistent.
5. Remove the dipstick
and read the oil level.
Maintain the oil level in
the normal operating
range (2). Do not overfill.
66
ADD 8 OZ.NORMALFULL
2
MAINTENANCE
Engine Oil
Oil an d Filter Chan ge
CAUTION
Contact with hot oil may result in serious burns. Do not allow hot
oil to come into contact with skin.
1. Position the vehicle on a level surface. Clean the area around the
drain plug at the bottom of the oil tank and the bottom of the
engine.
2. Run the engine for two to three minutes, then turn it off.
3. Place a drain pan beneath the oil tank and remove the drain plug
(1). Allow the oil to drain completely.
4. Install a new sealing washer (2) on the oil drain plug.
NOTE:The sealing surfaces on the drain plug and the oil tank
should be clean and free of burrs, nicks or scratches.
5. Reinstall the drain plug
and torque to 14-17 ft.
lbs. (19-23 Nm).
6. Disconnect the lower oil
delivery hose and remove
the screen fitting (3) from
2
1
the oil tank. Clean the
fitting.
NOTE:The fitting threads
must be sealed with
LOCTITE PST 505 or
PTFE seal tape.
4
7. Reinstall the screen fitting
and rotate the fitting
clockwise a minimum of
2 1/2 turns into the tank threads. Continue to rotate the fitting until
the nipple of the fitting aligns with the mark (4) on the tank.
NOTE:Do not over-tighten. Maximum torque for the screen fitting is
25 ft. lbs. (34 Nm).
8. Reattach the oil line.
3
67
MAINTENANCE
Engine Oil
Oil an d Filter Chan ge
9. Place shop towels beneath the oil filter. Using an oil filter wrench,
turn the filter (1) counterclockwise and remove.
10. Lubricate the gasket on the new filter with a film of new engine
oil. Check to make sure the gasket is in good condition. Also
make sure the gasket from the old filter is not still on the engine.
11. Install the new filter and tighten by hand 1/2 to 3/4 turn after
gasket contacts the engine.
12. Approximately one cup of
engine oil will remain in the
crankcase. To drain, remove
the drain plug on the lower
right side of the crankcase.
2
NOTE:Thesealingsurfaceson
the drain plug and
crankcase should be
clean and free of burrs,
nicks or scratches.
1
13. Reinstall the drain plug and
torque to 14 ft. lbs. (19 Nm).
14. Remove the dipstick (2) and add two quarts (1.9 l) of the
recommended oil. Reinstall the dipstick.
NOTE:If the sump is not drained, add about 1 3/4 quarts initially.
15. Place the gear selector in neutral. Lock the parking brake.
16. Prime the oil pump using the procedure on page 69.. Then stop
the engine and inspect for leaks.
17. Recheck the oil level on the dipstick and add oil as necessary to
bring it to the recommended level on the dipstick.
18. Dispose of used filter and oil properly.
68
Engine Oil
Oil an d Filter Chan ge
Oil Pump Priming
This priming procedure must be
performed whenever the oil hose
connection between the oil tank
and pump inlet has been
disconnected.
1. Clamp or pinch off the vent
line (1) approximately 2I
from the oil tank (2),
between the end of the oil
tank vent fitting and the vent
line’s pressure relief slit (3).
2. Run the engine for 10-20
seconds.
3. Remove the vent line clamp.
If the line is bled properly,
you should hear a rush of air,
indicating that the line is
properly primed and ready for
operation. If you do not hear
air, the line has not bled, and
you’ll need to repeat the
priming procedure.
MAINTENANCE
2I
1
2
3
69
MAINTENANCE
Transmission Oil
Always check and change the transmission oil at t he intervals outlined
in the Periodic Maintenance Chart beginning on page 60. Maintain the
oil level within the SAFE operating range on the dipstick. We
recommend the use of Premium AGL Synthetic Gearcase Lubricant.
See page 111 for the part numbers of Polaris products.
Oil Ch eck
The transmission oil dipstick (1)
is located on the right side of the
vehicle.
1. Position the vehicle on a
level surface.
2. Remove the dipstick and
wipe it clean.
3. Reinstall the dipstick
completely, then remove it
and check the level.
4. Add the recommended lubricant to
bring the level into the safe operating range (2).
5. Reinstall the dipstick.
1
2
70
MAINTENANCE
Transmission Oil
Refer to the specifications section beginning on page 108 for
transmission oil capacity.
Oil Change
1. Position the vehicle on a level surface.
2. Place a drain pan beneath the
transmission oil drain plug
area.
3. Loosen the jam nut (A).
4. Turn the adjuster bolt (B) in to
allow the removal of the drain
plug (C).
5. Remove the drain plug and
wipe the magnetic end clean to
remove accumulated metallic
filings.
6. After the oil has drained
completely, install a new
sealing washer and reinstall the drain plug. Torque to 14 ft. lbs.
(19 Nm).
7. Turn the adjuster bolt (B) out until it touches the frame, and then
turn an additional 1/2 turn.
8. Tighten the jam nut securely while holding the adjuster bolt.
9. Remove the dipstick. Add the recommended lubricant until the oil
level is between the upper and lower limits. Do not overfill.
10. Reinstall the dipstick.
11. Check for leaks.
A
C
B
71
MAINTENANCE
Drive Chain
The 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 s pray lube. See page 111 for the
part numbers of Polaris products.
CAUTION
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.
72
MAINTENANCE
Toe Alignment
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.
Use the following procedure to check the toe alignment of the vehicle.
The recommended toe alignment is 1/8″ -1/4″ (3-6 mm) toe out.
1. Position the vehicle on a level
surface.
2. Set the handlebars in a
straight-ahead position
and secure them in this
position.
3. Place a chalk mark on the
center line of the front
tires approximately 10″
(25.4 cm) from the floor,
or as close to the hub/axle
center line as possible.
Make sure both marks are
the same distance from
the floor.
4. Measure the distance between the marks and record the
measurement (A).
5. Move the vehicle until the chalk marks are at the rear of the tires,
even with the hub/axle centerline.
6. Measure the distance between the marks and record the
measurement (B).
7. Subtract measurement B from measurement A. The difference is
the vehicle toe-out alignment.
A
B
NOTE:If you discover improper alignment, see your Polaris dealer
for service.
73
MAINTENANCE
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.
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.
1. Always maintain brake fluid at an adequate level (see page 35).
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.
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 4 brake fluid. Do not
overfill.
74
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.
MAINTENANCE
NOTE:Pads should be changed when
worn to 3/64″ (.1 cm).
3/64″ (.1 cm)
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.
75
MAINTENANCE
Steering Assembly
The steering assembly of the vehicle 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.
1
NOTE:Accessory springs are
available through your
Polaris dealer.
Throttle Cable Freeplay
1. Locate the throttle cable adjuster
at the handlebar.
2. Squeeze the end of the rubber
boot (A) and slide it far enough to
expose the end of the inline
cable adjuster (B).
3. Loosen the adjuster locknut (C).
4. Rotate the boot to turn the
adjuster until 1/16″ to 1/8″
(1.5-3 mm) of freeplay is
achieved at the thumb lever.
NOTE:Move the throttle lever back
and forth while adjusting.
5. Tighten the locknut.
6. Reinstall the boot(s) to their original
position.
NOTE:Engine RPM should not
increase when steering is
turned full left or right.
Readjust cable freeplay if
this occurs.
A
C
B
1/16″ to 1/8″
(1.5-3 mm)
A
76
MAINTENANCE
Handlebars
WARNING
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.
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.
1
77
MAINTENANCE
Carburetor
IMPORTANT: Your Polaris vehicle is calibrated at t he factory for
optimal performance at altitudes ranging from zero to 6,000 feet (1800
m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above
6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and
the engine loses approximately 3% of its power for each 1000-foot
(304.8 m) increase in elevation. Although this power cannot be
regained, adjustments 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 vehicle 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 108 for the
proper setting.
NOTE:Turn the screw in (clockwise) to raise
RPM. Turn the screw out
(counterclockwise) to lower RPM.
78
1
MAINTENANCE
Wheels
WARNING
Operating your vehicle 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
vehicle 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.
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.
79
MAINTENANCE
Wheels
Wheel Installatio n
1. Place the transmission in gear and l ock t he parking brake.
WARNING
Improperly installed wheels can adversely affect tire wear and
vehicle handling, which can result in serious injury or death.
Always ensure that all nuts are torqued to specification. Do not
service axle nuts that have a cotter pin installed. See your
Polaris dealer.
2. Place the wheel on the wheel hub with the valve stem toward the
outside and rotation arrows on the tire pointing toward forward
rotation.
3. Install the wheel nuts and finger tighten. On vehicles with tapered
rear wheel nuts, make sure the tapered ends of the nuts fit into the
tapers on the wheels.
4. Lower the vehicle to the ground.
5. Torque the nuts to specification.
Wheel Nut Torque Specifications
Check the wheel nut torques occasionally and when they’ve been
loosened for maintenance.
Front
80
ItemSpecification
Front Wheel Nuts27 ft. lbs. (37 Nm)
Rear Wheel Nuts50 ft. lbs. (68 Nm)
Rear
50 ft. lbs.
(68 Nm)
27 ft. lbs.
(37 Nm)
MAINTENANCE
Wheels
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.
WARNING
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.
81
MAINTENANCE
Rear Drive Chain Slack
CAUTION
Adjusting or operating the vehicle 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.
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
3/16″-3/8″ (.48 cm - .95 cm)
1. Remove the chain guard.
2. Loosen the chain guide.
3. Loosen the two eccentric
locking bolts (1).
4. Loosen the caliper mounting
bolt located on the left side
of the swing arm.
5. Insert a pin punch (2) through the sprocket hub and into the
eccentric housing.
82
1
2
MAINTENANCE
Rear Drive Chain Slack
6. Roll the vehicle 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 15 ft. lbs. (20 Nm)
9. Remove the pin punch.
10. Roll the vehicle forward, checking chain tension in several places
around the chain.
1
NOTE:The chain is adjusted correctly when the tightest portion of
11. Position the chain guide to allow 1/8” (3mm) clearance and tighten
12. Reinstall the chain guard.
the chain has approximately 3/8” (10mm) deflection.
the retaining bolt to 5 ft. lbs. (7 Nm).
83
MAINTENANCE
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 111 for the
part numbers of Polaris products.
1
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.
84
MAINTENANCE
Engine Cooling System
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.
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
the 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
1
slowly add coolant through the
radiator filler neck.
3. Reinstall the pressure cap and s ecure 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. Contact your dealer for
the correct replacement part.
85
MAINTENANCE
Lights
When servicing a halogen lamp, don’t touch the lamp with bare
fingers. Oil from your skin leaves a residue, causing a hot spot that
will shorten the life of the lamp.
WARNING
Poor lighting while driving can result in severe injury or death.
Headlight and taillight lenses become dirty during normal
operation. Wash the headlights frequently to maintain lighting
quality.
Hot components can cause serious burns to skin. Do not service
the headlamps until they’ve cooled sufficiently.
Headlight Lamp Replacement
1. Remove the wire harness connector from the back of the headlight.
2. Grasp the bulb housing and turn it counterclockwise to remove the
bulb.
3. Apply dielectric grease to the light bulb socket before installing the
new bulb. Install the replacement bulb into headlight housing and
rotate clockwise firmly.
NOTE:The bulb must be positioned so the harness installs into the
4. Reinstall the connector to the back of the headlight..
lamp at the bottom.
High Beam Adjustment
The headlight beam can be adjusted vertically.
1. Position the vehicle on a level surface with the headlight
approximately 25 ft. (7.6 m) from a flat wall.
2. Measure the distance from the floor to the center of the headlight
and make a mark on the wall at the same height.
3. Start the engine and turn the headlight switch to high beam.
4. Observe the headlight aim on the wall. The most intense part of
the headlight beam should be aimed 2” (5.1 cm) below the mark
placed on the wall.
NOTE:Include rider weight on the seat when measuring.
5. Loosen the pivot bolt and adjust the beam to the desired position.
6. Tighten the bolt and torque to 60 in. lbs. (7 Nm).
86
MAINTENANCE
Lights
Taillight/Brakelight L a mp Replacement
If the taillight/brakelight does not work the lamp may need to be
replaced.
1. Remove the taillight lens cover
mounting screws. Remove the
lens cover and gasket and set
aside for reassembly.
2. Remove the lamp (1).
3. Apply dielectric grease to the
socket and install the new
lamp.
4. Test the taillight/brakelight for
proper operation.
5. Reinstall the gasket and lens cover.
Indicator L amp Replacement
1. Remove the instrument panel, if necessary, to access the back of
the indicator panel.
2. Using a small, straight-blade screwdriver, turn the base of the bulb
1/4 turn counterclockwise.
3. Using a needle-nose plier or similar tool, pull the lamp out of the
indicator panel housing.
4. Insert the new bulb and seat it by turning it 1/4 turn clockwise.
5. Reinstall the instrument panel if removed.
1
87
MAINTENANCE
Filter Systems
Air Filter Service
1. Remove the seat, release
the clips, and remove the
air box cover.
2. Loosen the clamp and remove
the filter.
3. Remove the fabric type pre-filter (1)
from the main filter (2). Wash the
pre-filter i n soapy water, then rinse
and let dry.
4. Reinstall the pre-filter over the main
filter. (Replace the main filter if needed.)
5. Reinstall the filter i nto the air box and tighten
the clamp. Do not over tighten the clamp, as filter damage could
occur.
Breather Filter/Hose
1
2
CAUTION
Operation of your vehicle without a breather filter can cause
engine damage. Always reinstall the breather filter after removing
for service.
1. Remove the clamps and pull the filter (1)
out of the hoses.
NOTE:It’s not necessary to remove the
lower hose from the engine.
2. Inspect the filter for debris. Blow
gently through the filter in the direction
of the arrow to check for clogging.
Replace if needed.
3. Check the hoses for cracks,
deterioration, abrasion, or leaks. Replace as needed.
4. Reinstall the filter and secure the clamps.
NOTE:The filter is effective with the arrow pointing in either
direction.
88
1
MAINTENANCE
Spark Plugs
Spark Plug Recommendations
CAUTION
Using non-recommended spark plugs can result in serious engine
damage. Always use Polaris-recommended spark plugs. Refer
to the specifications section beginning on page 108
Refer to the specifications section beginning on page 108 for the
recommended spark plug type and gap for your vehicle. Torque spark
plugs to specification.
Plug ConditionTorque Specification
New Spark Plug9-11 ft. lbs. (12-15 Nm)
Previously Installed Spark Plug17-20 ft. lbs. (23-27 Nm)
.
Spark Plug Inspection
Spark plug condition is indicative of engine operation. Check the spark
plug firing end condition after the engine has been warmed up and the
vehicle has been driven at higher speeds. Immediately check the spark
plug for correct color. See page 90.
WARNING
A hot exhaust system and engine can cause serious burns. Wear
protective gloves when removing a spark plug for inspection.
1. Remove the spark plug cap.
2. Using the special wrench provided in the tool pouch, rotate the
spark plug counterclockwise to remove it.
3. Reverse the procedure for spark plug installation. Torque to
specification.
89
MAINTENANCE
Spark Plugs
Spark Plug Inspection
Normal Plug
The normal insulator tip is gray, tan or light brown. There will be few
combustion deposits. The electrodes are not burned or eroded. This
indicates the proper type and heat range for the engine and the service.
NOTE:The tip should not be white. A white insulator tip indicates
overheating, caused by use of an improper spark plug or
incorrect carburetion adjustments.
Wet Fouled Plug
The wet fouled insulator tip is black. A damp oil film covers the firing
end. There may be a carbon layer over the entire nose. Generally, the
electrodes are not worn. General causes of fouling are excessive oil,
use of non-recommended injection oil, improper use of the choke, or
incorrect carburetion adjustments.
Recoil Housing
To prevent possible engine damage,
always drain the recoil housing (1)
after operating the vehicle in very
wet conditions. This should also be
done before storing the vehicle.
Water will enter the recoil housing
if the starter handle is disengaged
from the rope guide when under
water.
The drain screw is located at the
bottom of the recoil housing. Use a
wrench to remove the screw. Be sure to reinstall the screw after
draining the housing.
1
NOTE:Do not open the crankcase drain unless the engine has
ingested water. On 4-cycle engines, some engine oil will be
lost if the crankcase drain is opened.
90
MAINTENANCE
Vehicle Immersion
CAUTION
If your vehicle becomes immersed, major engine damage can
result if the machine is not thoroughly inspected. Take the
vehicle to your dealer before starting the engine.
If it’s impossible to take your Quadricycle to a dealer before starting it,
follow the steps outlined below.
1. Move the vehicle to dry land or at the
very least, to water below the
footrests.
2. Check the airbox for any water. Drain
and dry it if water is present.
3. Turn the fuel valve off.
4. Remove the spark plug.
5. Turn the engine over several times
using the electric start.
6. Loosen the carburetor drain screw (1).
7. Dry the spark plug and reinstall, or replace it with a new plug.
8. Tighten the carburetor drain screw.
9. Turn the fuel valve on.
10. Attempt to start the engine. If necessary, repeat the drying
procedure.
11. Take the vehicle to your dealer for service as soon as possible,
whether you succeed in starting it or not.
1
NOTE:If water has been ingested into the PVT, follow the procedure
on page 93 for drying out the PVT.
91
MAINTENANCE
PVT System
The basic operation of the Polaris PVT system is dependent on engine
speed and vehicle torque requirements. As engine speed increases, the
force exerted on the movable drive sheave by the flyweights also
increases. This, in turn, increases the amount of “pinch” applied to the
drive belt. Similarly, if the engine speed decreases, the amount of
centrifugal force decreases, reducing the amount of belt “pinch.” This
begins to occur at speeds of less than 5 MPH, due to the system’s
dependence on engine speed.
For example, when operating at a ground speed of 3 MPH, the engine
would be running at only about 1500 RPM, with an engagement speed
of about 1400 RPM. Whenever operating this close to the engagement
point, the engine may be running at a speed too low to provide the
adequate “pinch” needed to prevent incomplete engagement.
Incomplete engagement creates excessive heat that can destroy belts
and clutch covers. In some cases, excessive clutch wear and damage
may result.
If the vehicle will be operated for extended periods below 5 MPH, or
for towing loads, we recommend that you install a one tooth smaller
counter shaft sprocket to raise the operating RPM far enough above the
engagement RPM to reduce heat caused by incomplete engagement.
Reducing the temperature inside the clutch cover extends the life of the
PVT components (belt, cover, etc.).
NOTE:Avoid heavy p ulling and extended low-speed
operation.
92
MAINTENANCE
PVT System
WARNING
Failure to comply with the instructions in this warning can result in
severe injury or death.
Do not modify any component of the PVT system. Doing so may
reduce its strength so that a failure may occur at a high speed.
The PVT system has been precision balanced. Any modification
will cause the system to be out of balance, creating vibration and
additional loads on components.
The PVT system rotates at high speeds, creating large amounts
of force on clutch components. Extensive engineering and
testing has been conducted to ensure the safety of this product.
However, as the owner, you have the following responsibilities to
make sure this system remains safe:
Always follow all recommended maintenance procedures. See
your dealer as outlined in the owner’s manual.
This PVT system is intended for use on Polaris products only. Do
not install it in any other product.
Always make sure the PVT housing is securely in place during
operation.
PVT Drying
There may be some instances when water is accidently ingested into
the PVT system. Use the following instructions to dry it out before
operating:
1. Remove the drain plug and allow the water to drain. Reinstall the
drain plug.
2. Start the engine and shift the transmission into neutral. Apply
varying throttle for 10-15 seconds to expel the moisture and air-dry
the belt and clutches. Do not hold the throttle wide open for more
than 10 seconds.
3. Allow the engine RPM to settle to idle speed, then shift the
transmission to the lowest available range.
4. Test for belt slippage. If the belt slips, repeat the process.
5. Take the vehicle to your dealer for service as soon as possible.
93
MAINTENANCE
Spark Arrestor
WARNING
Failure to heed the following warnings while servicing the spark
arrestor could result in serious injury or death.
Do not perform service on the spark arrestor while the system is
hot. Exhaust system temperatures can reach 1000° F. Allow
components to cool sufficiently before proceeding.
Remove any combustible materials from the area.
Wear eye protection and leather work gloves.
Do not stand behind or in front of the vehicle while purging.
Never run the engine in an enclosed area. Exhaust contains
poisonous carbon monoxide gas.
Never go under the vehicle while it’s inclined.
1. Remove the arrestor clean-out
plug (1) from the bottom of the
muffler.
2. Place the transmission in neutral
and start the engine.
3. Purge carbon from the system by
momentarily revving the engine
several times.
4. If carbon is expelled, cover or plug the
exhaust outlet (2) and rap on the pipe around
the cleanout plug while revving the engine several more times.
5. If particles are still suspected to be in the muffler, elevate the rear
of the vehicle one foot higher than the front. Lock the parking
brake and block the wheels. Make sure the vehicle is in neutral
and repeat steps 3 and 4 until no more particles are expelled when
the engine is revved.
6. Stop the engine and allow the arrestor to cool. Reinstall the
arrestor plug and remove the outlet cover or plug.
2
1
94
MAINTENANCE
Battery
Your vehicle may have either a sealed battery, which requires little
maintenance, or a conventional battery. A sealed battery can be
identified by its flat covers on the top of the battery. A conventional
battery has six filler caps on the top of the battery.
Conventional Battery
Always keep battery terminals and connections free of corrosion. If
cleaning is necessary, remove corrosion with a stiff wire brush. Wash
with a solution of one tablespoon baking soda and one cup water.
Rinse well with tap water and dry off with clean shop towels. Coat the
terminals with dielectric grease or petroleum jelly. Be careful not to
allow cleaning solution or tap water into a conventional battery.
WARNING
Battery electrolyte is poisonous. It contains sulfuric acid. Serious
burns can result from contact with skin, eyes or clothing.
Antidote:
External: Flush with water.
Internal: Drink large quantities of water or milk. Follow with milk
of magnesia, beaten egg, or vegetable oil. Call physician
immediately.
Eyes: Flush with water for 15 minutes and get prompt medical
attention.
Batteries produce explosive gases. Keep sparks, flame,
cigarettes, etc. away. Ventilate when charging or using in an
enclosed space. Always shield eyes when working near
batteries. KEEP OUT OF REACH OF CHILDREN.
95
MAINTENANCE
Battery
WARNING
Improperly connecting or disconnecting battery cables can result
in an explosion and cause serious injury or death. When
removing the battery, always disconnect the negative (black)
cable first. When reinstalling the battery, always connect the
negative (black) cable last.
Battery Removal
1. Disconnect the hold-down strap holding the battery in position, and
remove battery cover.
2. On conventional batteries, remove the battery vent tube.
3. Disconnect the black (negative) battery cable first.
4. Disconnect the red (positive) battery cable next.
5. Lift the battery out of the vehicle. Be careful not to tip a conventional
battery sideways, which could spill electrolyte.
CAUTION
If electrolyte spills, immediately wash it off with a solution of one
tablespoon baking soda and one cup water to prevent damage to
the vehicle.
96
MAINTENANCE
Battery
Battery Installation
Using a new battery that has not been fully charged can damage the
battery and result in a shorter life. It can also hinder vehicle
performance. Follow the battery charging instructions on pages 99-101
before installing the battery.
1. Ensure that the battery is fully charged.
2. Place the battery in the battery holder.
3. With conventional batteries, install the battery vent tube (sealed
batteries do not have a vent tube).
NOTE:The vent tube must be free of obstructions and securely
installed. Route the tube away from the frame and vehicle
body to prevent contact with electrolyte.
WARNING
Battery gases could accumulate in an improperly installed vent
tube and cause an explosion, resulting in serious injury or death.
Always ensure that the vent tube is free of obstructions and is
securely installed as recommended.
4. On conventional batteries, coat the terminals with dielectric grease
or petroleum jelly.
5. Connect and tighten the red (positive) cable first.
6. Connect and tighten the black (negative) cable last.
7. Install the battery cover.
8. Secure the battery hold-down strap.
9. Verify that cables are properly routed.
NOTE:Cables should be safely tucked away at the front and rear of
the battery.
97
MAINTENANCE
Battery
Battery Storage
Whenever the vehicle is not used for a period of three months or more,
remove the battery from the vehicle, ensure that it’s fully charged, and
store it out of the sun in a cool, dry place. Check battery voltage each
month during storage and recharge as needed to maintain a full charge.
NOTE:Power plug leads may need to be bent down so that the
battery cover can be installed.
NOTE:Battery charge can be maintained by using a Polaris Battery
Tender charger or by charging about once a month to make
up for normal self-discharge. Battery T ender can be left
connected during the storage period, and will automatically
charge the battery if the voltage drops below a
pre-determined point. See page 111 for the part numbers of
Polaris products.
98
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