Polaris Sportsman 500 EFI User Manual

03
WARNING
product contains chemicals known
to cause cancer, birth defects or
other reproductive harm.
A card containing important ATV safety information should be attached to the owner’s manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800-342-3764 for assistance.
WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products.
S Snowmobiles S All-terrain vehicles (ATVs) 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 2005 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.
Printed in U.S.A.
2006 Sportsman 500 EFI Owner’s Manual P/N 9920012
2
TABLE OF CONTENTS
VEHICLE IDENTIFICATION NUMBERS 5.......
SAFETY 6...................................
CONTROLS 31...............................
FEATURES 39...............................
OPERAT ION 46..............................
EMISSION CONTROL SYSTEMS 63............
MAINTENANCE AND LUBRICATION 64........
ADJUSTMENTS 105..........................
POLARIS PRODUCTS 107....................
TROUBLESHOOTING 108.....................
SPECIFICATIONS 112........................
WARRANTY 114.............................
MAINTENANCE LOG 120.....................
INDEX 122...................................
3
4
VEHICLE IDENTIFICATION NUMBERS
Record your ATV’s identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys, so if both keys are lost, the ignition switch must be replaced.
2
Vehicle Model Number:
Frame VIN (1):
Engine Serial Number (2):
Key Number (3):
1
31XX
3
5
SAFETY
Safety Decals and Locations
Warning decals have been placed on the ATV for your protection. Read and follow the instructions of the decals on the ATV carefully. If any of the decals depicted in this manual differ from the decals on your ATV, always read and follow the instructions of the decals on the ATV.
If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal.
WARNING
Improper AT V use can result in SEVERE INJURY or DEAT H
ALWAYS USE
AN APPROVED
HELMET AND PROTECTIVE
GEAR
NEVER operate:
ALW AYS:
NEVER USE ON PUBLIC
ROADS
NEVER CARRY
PASSENGERS
WARNING
NEVER USE WITH DRUGS OR ALCOHOL
7172560
7172561
6
Safety Decals and Locations
WARNING
IMPROPER TIRE PRESSURE OR OVERLOADING can c ause loss of control resulting in SEVERE INJURY OR DEATH.
TIRE PRESSURE IN PSI (KPa): FRONT 5 (34,5) REAR 5 (34,5)
MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING MACHINE, DRIVER AND CARGO IS 1200 LBS. (545 kg).
Reduce speed and allow greater dis tance for braking when carrying cargo. Overloading or carrying tall, off-center, or unsecured loads will increase your risk of losing control. Loads s hould be c entered, 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 l oad extends over the side of the rack.
Read Owner’s Manual for more detailed loading information
7172748
SAFETY
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.
7172559
ATTENTION
S Operation of this vehicle without the air filter
element will severely damage the engine.
S Clean pre-filter element often, more
frequent cleaning required in dusty conditions. Do not operate vehicle without pre-filter.
7172921
7
SAFETY
Safety Decals and Locations
WARNING
S Moving parts hazar d under belt-clutch guard. To
prevent s erious injury, do not operate vehicle with guard r emoved.
S Do not modify engine or clutch. Doing so can
cause part failure, possible imbalance, and excessive engine RPM, which can result in serious injury or death.
NO STEP
7172563
WARNING
S DO NOT TOW FROM RACK OR BUMPER.
Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch.
S Max Rack Loads: Front 90 lbs. (41 kg) Rear 180 lbs. (82 kg)
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.
7172559
7172572
8
Safety Decals and Locations
SAFETY
WARNING
Pushing reverse override button may cause sudden increases in power and traction if too much throttle is applied. Loss of control or forward flipover may result, especially in AWD. See Owner’s Manual.
7172564
MANUFACTURED BY: POLARIS IND. INC.
DATE:
VIN:
THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT INTENDEDFOR USE ON PUBLIC ROADS.
CE VÉHICULE EST UN VÉHICULE TOUT TERRAIN QUI NiEST PAS DESTINÉ À ÊTRE UTILISÉ SUR LES CHEMINS PUBLICS.
Canadian Certification Decal
ALL WHEEL
Do not push s witch t o engage AWD if the rear wheels are spinning. This may cause severe drive shaft and clutch damage. See your Owner’s Manual.
DRIVE
SWITCH
7079780
7171492
TRAILER MAX WEIGHT: 1225 LBS. (557 KG) ON LEVEL GROUND 850 LBS. (386 KG) UP TO 15° GRADE
HITCH MAX. VERTICAL WEIGHT: 120 LBS. (55KG)
7170911
9
SAFETY
Safe Riding Gear
Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury.
1. Helmet
Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injury.
Select an approved helmet that meets or exceeds your state’s safety standards and bears either the Department of Transportation (DOT) label, the American National Standards Institute label (ANSI z90.1), or the Snell Memorial Foundation label.
2. Eye Protection
Do not depend on sunglasses for proper eye protection. A pair of goggles or a helmet face shield offer the best protection for your eyes. They should be kept clean and be of shatterproof design (bearing the markings Z2.1 or VESC 8).
1
2
3
5
4
3. Gloves
Off-road style gloves with knuckle pads are the best for comfort and protection.
4. Boots
The best footwear is a pair of strong over-the-calf boots with heels, like moto-cross boots.
5. Clothing
Always wear long sleeves and long pants to protect arms and legs. Riding pants with kneepads and a jersey with shoulder pads provide the best protection.
10
SAFETY
Operator Safety
WARNING
Failure to follow the warnings contained in this manual can result in serious injury or death.
A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.
Read and understand your owner’s manual and all warnings before operating a Polaris ATV.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age.
Know 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.
Safety Training
When you purchased your new ATV, your dealer offered a hands-on safety training course that covers all aspects of vehicle safety. You were also provided with printed materials that explain safe operating procedures. You should review this information on a regular basis.
If you purchased a used Polaris ATV from a party other than a Polaris dealer, you can request this free safety training from any authorized Polaris dealer.
A Polaris ATV is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of the ATV in your area.
We strongly advise you to strictly follow the recommended maintenance program outlined in your owner’s manual. This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals.
11
SAFETY
Operator Safety
The following two pages identify signal words and symbols that appear in this manual. 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.
12
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 an ATV without proper instruction. Take a training
course. Beginners should receive training from a certified instructor.
Contact an authorized Polaris ATV dealer or call Polaris at 1-800-342-3764 to find out about the training courses nearest you.
S Never allow anyone under 16 years of age to operate this ATV. S Never permit a guest to operate the ATV unless the guest has read
this manual and all product labels and has completed a certified safe­ty training course.
S Always avoid operating an ATV on paved surfaces, including side-
walks, driveways, parking lots, and streets.
S Never operate an ATV on a public street, road or highway, including
a dirt or gravel road.
S Never operate an ATV without wearing an approved helmet that fits
properly. Always wear eye protection (goggles or face shield), gloves, boots, a long-sleeved shirt or jacket, and long pants.
S Never consume alcohol or drugs before or while operating an ATV. S Never operate at excessive speeds. Travel at speeds appropriate for
the terrain, visibility and operating conditions, and your experience.
S Never attempt wheelies, jumps or other stunts. S Always inspect your ATV before each use to make sure it’s in safe
operating condition. Always follow the inspection and maintenance procedures and schedules outlined in your owner’s manual.
S Always keep both hands on the handlebars and both feet on the foot-
rests of the ATV during operation.
S Always travel slowly and use extra caution when operating on unfa-
miliar 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.
13
SAFETY
Operator Safety
S Always have the ATV inspected by an authorized Polaris dealer if
it’s been involved in an accident.
S Never operate on hills too steep for the ATV or for your abilities.
Practice on smaller hills before attempting larger hills.
S Always follow proper procedures for climbing hills. Check the ter-
rain carefully before ascending a hill. Never climb hills with exces­sively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. Never go over the top of a hill at high speed.
S Always follow proper procedures for going downhill and for braking
on hills. Check the terrain carefully before you start down a hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle, which would cause the vehicle to lean sharply to one side. Travel straight down the hill when pos­sible.
S Always follow proper procedures for crossing the side of a hill.
Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you’ve mastered (on level ground) the turn­ing t echnique outlined in this manual. Avoid crossing the side of a steep hill when possible.
S Always use proper procedures if you stall or roll backwards while
climbing a hill. To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Always dismount on the uphill side, or to either side if the ATV is pointed straight uphill. Turn the ATV around and remount following the procedure described in this manual.
S Always check for obstacles before operating in a new area. Never
attempt to operate over large obstacles, such as rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual.
S Always be careful of skidding or sliding. On slippery surfaces like
ice, travel slowly and use extra caution to reduce the chance of skid­ding or sliding out of control.
S Avoid operating the ATV through deep or fast-flowing water. If it’s
unavoidable, travel slowly, balance your weight carefully, avoid sud­den movements, and maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make sudden throttle changes.
14
SAFETY
Operator Safety
S Wet brakes may have reduced stopping ability. Test the brakes after
leaving water. If necessary, apply them lightly several times to allow friction to dry out the pads.
S Always check for obstacles or people behind t he ATV before operat-
ing in reverse. When it’s safe to proceed in reverse, move slowly and avoid turning at sharp angles.
S Always use the size and type of tires specified for your ATV, and
always maintain proper tire pressure.
S Never modify an ATV through improper installation or use of acces-
sories.
S Never exceed the stated load capacity for your ATV. Cargo must be
properly distributed and securely attached. Reduce speed and follow the instructions in this manual for carrying cargo or towing. Allow a greater distance for braking.
FOR MORE INFORMATION ABOUT ATV SAFETY, call the Con­sumer Product Safety Commission at 1-800-638-2772, or call Polaris at 1-800-342-3764.
Equipment Modifications
We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes. Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury.
The warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle, or if any modifications have been made to the vehicle, that increase its speed or power.
NOTE: The addition of certain accessories, including (but not limited
to) mowers, blades, tires, sprayers, or large racks, may change the handling characteristics of the vehicle. Use only Polaris-approved accessories, and familiarize yourself with their function and effect on the vehicle.
15
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN The risk of an accident is greatly increased if the operator does
not know how to operate the ATV properly in different situations and on different types of terrain.
HOW TO AVOID THE Beginning and inexperienced operators should complete the
certified training course offered by Polaris. Operators should regularly practice the skills learned in the course and the operating techniques described in the owner’s manual.
For more information about the training course, contact an authorized ATV dealer or call Polaris at 1-800-342-3764.
HAPPEN
HAZARD
WARNING
POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN Severe injury and/or death could occur if a child under the
minimum age recommendation operates an ATV. Even though a child may be within the recommended age group
for operating some ATVs, he/she may not have the skills, abilities, or judgment needed to operate an ATV safely and could be susceptible to accident or injury.
HOW TO AVOID THE No one under the age of 16 should operate a Polaris ATV.
HAPPEN
HAZARD
16
Operator Safety
WARNING
POTENTIAL HAZARD Carrying a passenger on an
ATV. WHAT CAN Carrying a passenger
greatly reduces the operator’s ability to balance and control the ATV, which could cause an accident and injury to the operator and/or passenger.
HOW TO AVOID THE Never carry a passenger. The purpose of the long seat is to
allow the operator to shift position as needed during operation. It is not intended for carrying passengers.
HAPPEN
HAZARD
WARNING
POTENTIAL HAZARD Operating an ATV
on paved surfaces, including sidewalks, paths, parking lots, and driveways.
WHAT CAN ATV tires are designed for
off-road use. Operating on paved surfaces may seriously affect the handling and control of the ATV and could result in loss of control, accident, and/or injury.
HOW TO AVOID THE Avoid operating the ATV on pavement. If it’s unavoidable, travel
slowly and avoid sudden turns or stops.
HAPPEN
HAZARD
SAFETY
17
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD Operating this ATV on
public streets, roads or highways.
WHAT CAN The ATV could collide
with another vehicle. HOW TO AVOID THE Never operate the ATV on any
public street, road or highway, including dirt and gravel roads. In many states it’s illegal to operate ATVs on public streets, roads and highways.
HAPPEN
HAZARD
WARNING
POTENTIAL HAZARD Operating this ATV without
wearing an approved helmet, eye protection and protective clothing.
WHAT CAN Operating an ATV without
an approved helmet increases the risk of a severe head injury or death in the event of an accident.
Operating without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident.
HOW TO AVOID THE Always wear an approved helmet that fits properly. Always wear eye protection (goggles or face shield), gloves,
boots, long-sleeved shirt or jacket, and long pants.
HAPPEN
HAZARD
18
Operator Safety
WARNING
POTENTIAL HAZARD Operating the ATV after consuming
alcohol or drugs. WHAT CAN Consumption of alcohol and/or drugs
could seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected.
Consuming alcohol and/or drugs before or while operating an ATV could result in an accident causing severe injury or death.
HOW TO AVOID THE Never consume alcohol or drugs before or while operating an
ATV.
HAPPEN
HAZARD
WARNING
POTENTIAL HAZARD Operating the ATV at excessive speeds. WHAT CAN Excessive speed increases the operator’s chance of losing
control of the ATV, which can result in an accident. HOW TO AVOID THE Always operate the ATV at a speed that’s proper for the terrain,
visibility and operating conditions, and your experience.
HAPPEN
HAZARD
SAFETY
19
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD Attempting wheelies, jumps
and other stunts. WHAT CAN Attempting stunts increases
the chance of an accident, including an overturn.
HOW TO AVOID HAZARD
Never attempt wheelies, jumps, or other stunts. Avoid exhibition driving.
HAPPEN
THE
WARNING
POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the A TV. WHAT CAN Poor maintenance increases the possibility of an accident or
equipment damage. HOW TO AVOID THE Always inspect your ATV before each use to make sure it’s in
safe operating condition. Always follow the inspection and maintenance procedures and
schedules described in the owner’s manual.
HAPPEN
HAZARD
20
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 ATV. If the operator’s foot is not firmly planted on the footrest, it could
come into contact with the rear wheels and lead to accident or injury.
HOW TO AVOID THE Always keep both hands on the handlebars and both feet on the
footrests of the ATV during operation.
HAPPEN
HAZARD
WARNING
POTENTIAL HAZARD Failure to use extra
caution when operating the ATV on unfamiliar terrain.
WHAT CAN Unfamiliar terrain may
contain hidden rocks, bumps, or holes that could cause loss of control or overturn.
HOW TO AVOID THE Travel slowly and use extra caution when operating on unfamiliar
terrain. Always be alert to changing terrain conditions.
HAPPEN
HAZARD
21
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 ATV 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
22
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 A TV or for your abilities.
Never operate the ATV 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 ATV on hills steeper than 25_. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly while traveling uphill. The ATV
could flip over backwards. Never go over the top of any hill at high speed. An obstacle, a
sharp drop, or another vehicle or person could be on the other side of the hill.
HAPPEN
THE
SAFETY
23
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD Traveling downhill
improperly. WHAT CAN Improperly descending a hill
could cause loss of control or overturn.
HOW TO AVOID 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 57.
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
24
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 ATV around on any hill until you’ve mastered the turning technique (on level ground) as described in the owner’s manual. See page 58. Use extra caution when turning on any hill.
Avoid crossing the side of a steep hill. When crossing the side of a Always follow proper procedures as described in the owner’s
manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.
HAPPEN
THE
hill:
SAFETY
25
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD Stalling, rolling backwards
or improperly dismounting while climbing a hill.
WHAT CAN The vehicle could overturn. HOW TO AVOID
HAZARD Maintain steady speed
when climbing a hill. If all forward speed is Keep your weight uphill. Apply the brakes. Lock the parking brake when fully stopped. If the ATV begins rolling Keep weight uphill. Never apply engine power. Never apply the rear brake while rolling backwards. Apply the single-lever brake gradually. When fully stopped, apply the rear brake as well, and then lock
the parking brake. Dismount on uphill side, or to either side if ATV is pointed straight
uphill. Turn the ATV around and remount, following the procedure
described in the owner’s manual. See page 58.
HAPPEN
THE
lost:
backwards:
26
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 ATV could overturn. HOW TO AVOID THE On slippery surfaces such as ice, travel slowly and use extra
caution to reduce the chance of skidding or sliding out of control.
HAPPEN
HAZARD
SAFETY
WARNING
POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN The ATV could collide with an obstacle or person, resulting in
severe injury. HOW TO AVOID THE Before shifting into reverse gear, always check for obstacles or
people behind the ATV. When it’s safe to proceed, back slowly.
HAPPEN
HAZARD
27
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD Operating the ATV through deep or fast-flowing water. WHAT CAN Tires may float, causing loss of traction and loss of control, which
could lead to an accident or overturn. HOW TO AVOID THE Avoid operating the ATV through deep or fast-flowing water. If it’s
unavoidable to enter water that exceeds the recommended maximum depth (see page 59), 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 ATV with improper tires, or with improper or
uneven tire pressure. WHAT CAN Use of improper tires, or operation of the ATV with improper or
uneven tire pressure, could cause loss of control or accident. HOW TO AVOID THE Always use the size and type of tires specified for the ATV. Always maintain proper tire pressure as specified.
HAPPEN
HAZARD
28
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD Operating the ATV with improper modifications. WHAT CAN Improper installation of accessories or modification of the ATV
may cause changes in handling which could lead to an accident. HOW TO AVOID THE Never modify the ATV through improper installation or use of
accessories. All parts and accessories added to the vehicle must be genuine Polaris Industries Inc. or equivalent components designed for use on this ATV and should be installed and used according to approved instructions. See your authorized Polaris ATV dealer for more information.
HAPPEN
HAZARD
WARNING
POTENTIAL HAZARD Overloading the ATV or carrying/towing cargo improperly. WHAT CAN Overloading and towing can cause changes in vehicle handling,
which could lead to loss of control or an accident. HOW TO AVOID THE Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow a
greater distance for braking. Always follow the instructions in the owner’s manual for carrying
cargo or pulling a trailer. See page 50.
HAPPEN
HAZARD
WARNING
POTENTIAL HAZARD Operating on frozen bodies of water. WHAT CAN Severe injury or death can result if the ATV and/or the operator
fall through the ice. HOW TO AVOID THE Never operate the ATV on a frozen body of water.
HAPPEN
HAZARD
29
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.
30
CONTROLS
Engine Electrical Switches
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.
4
2
1
Mode/Reverse Override Switch (1) - This vehicle is equipped with a reverse speed limiter system. To gain additional power while backing, depress the override switch.
3
NOTE: The override switch also allows activation of AWD in reverse,
if the AWD switch is on. This switch is also used to toggle through the different modes of the rider information center. See page 40.
Engine Stop Switch (2) - The engine will
OFFOFF
not start or run when the switch is in the
RUN
OFF position. Its purpose is to provide the operator with a quick means of engine shutdown in case of an emergency.
Main Switch (3) - To start the engine, slide
2
the stop switch to the center RUN position and turn the m ain key switch clockwise past the ON position. Release t he key when the engine starts.
NOTE: Both the main switch and the emergency engine stop switch
will shut off all electrical power to the vehicle, including lights. To stop the engine, slide the stop switch either right or left to the OFF position.
Worklight Switch (4) - The worklight switch controls a light located at the rear of the vehicle. Use the rear light when additional light is needed for loading and unloading the vehicle. Turn the rear worklight off when driving the ATV.
31
CONTROLS
WARNING
Operating an ATV with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death.
Never start or operate an ATV with a sticking or improperly operating throttle. Always contact your dealer for service if throttle problems arise.
Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation. Always check the lever for free movement and return before starting the engine. Also check occasionally during operation.
Throttle Lever
Engine speed and vehicle movement are controlled by pressing the throttle lever (1). The throttle lever is spring loaded. Engine speed returns to idle when the lever is released.
This ATV is equipped with Polaris Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the throttle cable should stick in an open position when the operator releases the throttle lever, the engine will stop, and power to the rear wheels will cease.
1
WARNING
The Electronic Throttle Control (ETC) stops the engine in the event of a throttle system malfunction and is provided for your safety. Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms.
32
CONTROLS
Light Switches
The light switch is located on the left handlebar. It’s used to turn the lights on and off and to switch the lights from HI to LO.
NOTE: The lights won’t work unless the key is in the ON position
and the shut-off switch is in the RUN position.
WARNING
Operating the ATV on streets or roads, especially in darkness, could result in an accident and serious injury or death.
Your ATV is not equipped with highway-approved lights. It’s designed for and must be used for off-road use only. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness.
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
WARNING
Operating the ATV with a spongy brake lever can result in loss of braking, which could cause an accident.
Never operate the ATV with a spongy-feeling brake lever.
33
CONTROLS
Master Cylinder
The brake fluid in the master cylinder (1), which is located on the left handlebar, should be checked before each ride. The fluid level can be seen through an indicator window (2) on the top of the master cylinder. This eye will appear dark when the fluid level is full. When fluid needs to be added, the eye will be clear.
NOTE: When checking the fluid level, the A TV must be on level
ground with the handlebars straight. If the fluid level is low add DOT 3 brake fluid only. See page 107 for the part numbers of Polaris products.
1
WARNING
After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of accident or severe injury.
2
34
CONTROLS
Parking Brake
WARNING
Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating.
Setting the Parking Brake
1. Place the transmission in PARK.
2. Squeeze and release the brake lever (1) two or three times, then squeeze and hold.
3. Push the park brake lock (2) forward to engage the brake. Release the brake lever.
4. To release the parking brake lock, squeeze and release the brake lever. It will return to its unlocked position.
Important Safeguards
S The parking brake may relax if left on for a l ong period of time. Al-
ways block the wheels to prevent rolling.
S Always block the wheels on the downhill side of the ATV if leaving
it parked on a hill. Another option is to park the ATV in a sidehill position.
S Never depend on the parking brake alone if the ATV is parked on a
hill. Always block the wheels to prevent rolling.
1
2
35
CONTROLS
Auxiliary Brake
WARNING
Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death.
Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward. The rear wheels may skid and slide sideways, causing loss of control and serious injury or death.
Your Polaris ATV has an auxiliary brake (1) for added safety. It’s located on the inside of the right floor board and is operated by the right foot. The auxiliary brake serves as a backup to the main brake system if the main system becomes inoperative.
If the rear wheels slide while using t he auxiliary brake, reduce brake pedal pressure to brake the rear wheels without skidding.
Brake Fluid Level
Check the brake fluid level frequently for t he auxiliary brake system. The reservoir is located under the seat or near the auxiliary brake. Maintain the fluid level between the maximum and minimum marks.
1
36
Fuel T ank
The fuel tank filler cap (1) is located directly below the handlebar. Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane.
Fuel Filter
The in-line fuel filter should be replaced by your dealer after every 200 hours of operation and any time the fuel becomes contaminated with dirt or debris. Do not attempt to clean the fuel filter.
CONTROLS
1
37
CONTROLS
Automatic Transmission Gear Selector
The transmission gear selector (1) is located on the right side of the vehicle. Shift patterns vary, depending on your model.
H: High Gear L: Low Gear N: Neutral R: Reverse P: Park
1
H L
N R P
CAUTION
Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage.
To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear.
Whenever the ATV is left unattended, always place the transmission in PARK and lock the parking brake.
Belt Life
T o extend belt life, use low forward gear in heavy pulling situations and when operating at less than seven miles per hour for extended periods of time.
38
FEATURES
All Wheel Drive (AWD) System
The All Wheel Drive system is activated by the A WD switch (1) on the right handlebar. When the switchison2X4,theATVisin two-wheel drive at all times. When the switch is on AWD, the ATV is in all wheel drive and the AWD indicator light in the instrument cluster will be on.
When in AWD, the front gearcase will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the front gearcase will automatically disengage.
NOTE: The override switch allows activation of AWD in reverse if the
AWD switch is on. See page 31.
There is no limit to the length of time the vehicle may remain in AWD.
Engaging F ront Gearcase
The AWD switch may be turned on or off while the vehicle is moving. Initially, the vehicle’s electronic system will not enable the AWD until the engine RPM is below 3100. Once enabled, the AWD remains enabled until the AWD switch is turned off. If the switch is turned off while the front gearcase is moving, it will not disengage until the rear wheels regain traction.
Engage the AWD switch before getting into conditions where front wheel drive may be needed. If the rear wheels are spinning, release the throttle before switching to AWD.
1
CAUTION
Switching to AWD while the rear wheels are spinning may cause severe drive shaft and gearcase damage. Always switch to AWD while the rear wheels have traction or are at rest.
39
FEATURES
Instrument Cluster
Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in miles or kilometers as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV’s speed to approximately 7-9 mph. Refer to page 31 for additional information.
3
2
1
1. Rider Information Center
2. Speedometer needle - in addition to showing vehicle speed, the needle flashes when a warning condition exists.
3. Speedometer
CAUTION
To prevent damage, wash the ATV by hand or with a garden hose using mild soap. Do not use alcohol to clean the instrument cluster. Immediately clean off any gasoline that splashes on the instrument cluster. Do not allow insect sprays to come into contact with the lens.
40
FEATURES
Instrument Cluster
Rider Information Center
The rider information center is located in the instrument cluster. All segments will light up for 2.5 seconds at start-up.
NOTE: If the instrument cluster fails to illuminate, a battery
over-voltage may have occurred and the instrument cluster may have shut off to protect the cluster’s electrical system. If this occurs, take the ATV to your Polaris dealer for proper diagnosis.
1. Gear Indicator - As the shift lever is moved, this indicates the gear the transmission is in:
H = High Range
3
L = Low Range N = Neutral R = Reverse P=Park
2
2. AWD Indicator - This indicator illuminates when the electrical portion of the AWD system is enabled.
3. Engine Hour Display Indicator
4. Service Interval/Diagnostic Mode Indicator
5. Low Battery or Over Voltage - This warning usually indicates that the ATV is being operated at an RPM too low to keep the battery charged. A low battery warning may also occur under normal operation if the machine is at idle and high electrical load (lights, cooling fan, accessories) is applied. Driving at a higher RPM or connecting a battery charger will usually clear the warning.
6. Odometer/Tachometer/Tripmeter/ Hour Meter
7. Fuel Gauge - The segments of the fuel gauge show the level of fuel in the fuel tank. When the last segment clears, a low fuel warning is activated. All segments will flash, “FUEL” will display in the LCD, and the speedometer needle will blink. Refuel immediately.
8. Check Engine Warning Indicator - This indicator serves two purposes. The word HOT displays if the engine overheats. It also appears if an EFI-related fault occurs. Do not operate the A TV if this warning appears. Serious engine damage could result.
9. Mode Indicator
4
5
6
9
1
7
8
41
FEATURES
Instrument Cluster
Rider Information Center
The rider information center has 4 standard modes: Mode 1 - Odometer Mode 2 - Tripmeter Mode 3 - Total Service Hours Mode 4 - Tachometer The reverse override button on the left handlebar is also the mode
button.
NOTE: If using the mode button to program the rider information
center, or to toggle through the options, the machine cannot be in reverse.
Mode 1 - Odometer
The odometer records the miles traveled by the ATV.
Mode 2 -Trip Meter
The trip meter records the miles traveled by the ATV on each trip if it’s reset before each trip. To reset the trip meter, select the trip meter mode. Press and hold the mode button (override button) until the total changes to 0.
NOTE: In the Rider Information Center, the trip meter display
contains a decimal point, but the odometer displays without a decimal point.
Mode 3 - Hour Meter
This mode logs the total hours the engine has been in operation.
Mode 4 - Tachometer
The engine RPM is displayed digitally.
NOTE: Small fluctuations in the RPM from day to day may be
normal because of changes in humidity, temperature, elevation and electrical loads.
42
FEATURES
Instrument Cluster
Rider Information Center
Diagnostic Mode
The diagnostic mode is for informational purposes only. Please return your ATV to your dealer for all major repairs.
As long as the gauge is in the diagnostic mode, the wrench icon will remain lit.
To leave the diagnostic mode, turn the key switch off and on.
NOTE: Any movement of the tires will also take the machine out of
the diagnostic mode.
To enter the diagnostics mode:
1. Turn the key switch off and wait 10 seconds.
2. Set t he park brake and shift the transmission to neutral.
3. Hold the mode/reverse override button and turn the key switch on.
4. Release the switch as soon as the display is activated.
The initial screen display refers to the software version installed in your ATV. This information is displayed briefly.
Use the mode/reverse override button to toggle through the diagnostic screens.
Screen 1: Battery voltage
Screen 2: Tachometer
Screen 3: AWD diagnostic
This gauge indicates whether or not current is flowing through the AWD coil (only on models with switchable AWD).
Screen 4: Gear circuit diagnostic This screen displays the resistance value (in ohms) being read at the
gear switch input of the gauge.
43
FEATURES
Instrument Cluster
Rider Information Center
Diagnostic Mode
Screen 5: Programmable service interval The purpose of the programmable service interval is to provide the
consumer and dealer with a convenient reminder for routine maintenance. When your vehicle leaves the factory, this feature is set at 50 hours. You m ust enable the programmable service interval before it can be used.
Once the service interval mode is set with the hours when service is due, the hours of actual engine operation are subtracted from the set hours until 0 is reached. When the counter reaches 0, the wrench icon will flash quickly for 5 seconds each time the vehicle is started as a reminder that the periodic maintenance is due.
To set the hours, press and hold the mode/override button until the wrench icon flashes. When it begins to flash, release the button. The setting will increase by one hour each time the button is pressed. Pressing and holding the button will allow the numbers to escalate much faster. When the desired time increment is displayed, release the button and wait for the wrench to stop flashing. When the wrench stops blinking, your service hours are set.
NOTE: If you scroll past the intended number, hold the button down
If the service interval is enabled on your ATV and you wish to turn it off, toggle to the service interval mode. Press and hold the mode button for approximately 7 seconds until the word OFF appears in the Rider Information Center.
Screen 6: Miles/Kilometers toggle The display in the tripmeter and odometer can be changed to display
either kilometers or miles. The current display mode will be shown as KM or MP. To change, hold in the mode button until the letters flash, then press and release the button once. When the display stops flashing, the mode has been set.
44
until the count turns over to 0. You can then reset the number.
FEATURES
Instrument Cluster
Rider Information Center
Special EFI Diagnostic Mode
The EFI diagnostic mode is for informational purposes only. Please see your Polaris dealer for all major repairs. To download blink codes (failure codes) from the EFI module:
1. Place the transmission in PARK, turn the engine off and turn the key switch to the ON position.
2. Turn the key switch off and on three times in less than five seconds, then leave the switch on. Any blink code numbers stored in the EFI module will display, one at a time, in the alphanumeric display. The number “61” and the word “END” will display after all codes have been transmitted.
Blink Code
- No RPM Signal
21 Loss of Synchronization 54 Engine Temp Lamp: Short Circuit
45 Barometric Pressure Sensor:
46 Barometric Pressure Sensor:
22 TPS: Open or Short Circuit to
22 TPS: Short Circuit to Battery 55 Diag Lamp: Short Circuit to
23 RAM Error: Defective ECU 56 Pump Relay: Open Load
42 Engine Temp Sensor Circuit:
42 Engine Temp Sensor Circuit:
51 Injector 1: Open Load 41 Intake Air Temp Sensor: Open or
51 Injector 1: Short Circuit to Ground 41 Intake Air Temp Sensor: Short
51 Injector 1: Short Circuit to Battery 61 END
52 Injector 2: Open Load
52 Injector 2: Short Circuit to Ground
52 Injector 2: Short Circuit to Battery
Failure Description Blink
Circuit Low Input
Circuit High Input
Ground
Short to Ground
Open or Short to Battery
Code
54 Engine Temp Lamp: Open Load
54 Engine Temp Lamp: Short Circuit
55 Diag Lamp: Open Load
55 Diag Lamp: Short Circuit to
56 Pump Relay: Short Circuit to
56 Pump Relay: Short Circuit to
Failure Description
to Ground
to Battery
Ground
Battery
Ground
Battery
Short Circuit to +Sensor Voltage
Circuit to Ground
45
OPERATION
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.
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.
46
OPERATION
Break-In Period
The break-in period for your new Polaris ATV 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 and Drivetrain Break-in
1. Fill the fuel tank with gasoline. See page 37.
2. Check the oil reservoir level on the dipstick. See page 71. Add oil if necessary to maintain the level between the safe and add marks.
3. Drive slowly at first. Select an open area that allows room to familiarize yourself with vehicle operation and handling.
4. Vary the throttle positions. Do not operate at sustained idle.
5. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride inspection checklist. See page 48.
6. Pull only light loads.
7. During the break-in period, change both the oil and the filter at 20 hours, 200 miles, or one month, whichever comes first.
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.
47
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
Item Remarks See
Page
Brake system / lever travel Ensure proper operation 33, 80
Brake fluid Ensure proper level 34
Auxiliary brake Ensure proper operation 36
Front suspension Inspect, lubricate if necessary 69
Rear suspension Inspect, lubricate if necessary 69
Steering Ensure free operation --
Tires Inspect condition and pressure 84
Wheels / fasteners Inspect, ensure fastener tightness 85
Frame nuts, bolts, fasteners Inspect, ensure tightness --
Fuel and oil Ensure proper levels 71
Coolant level (if applicable) Ensure proper level --
Coolant hoses (if applicable) Inspect for leaks --
Throttle Ensure proper operation 32,106
Indicator lights / switches Ensure operation 33
Engine stop switch Ensure proper operation 31
Air filter, pre-filter Inspect, clean 86
Air box sediment tube Drain deposits whenever visible --
Headlamp Check operation, apply Polaris dielec-
tric grease when lamp is replaced
Brake light / tail lamp Check operation, apply Polaris dielec-
tric grease when lamp is replaced
Riding gear Wear helmet, goggles, protective
clothing
87
90
10
48
OPERATION
Starting the Engine
WARNING
Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area.
1. Position the vehicle on a level surface with the transmission in
PARK.
2. Lock the park brake, sit on the vehicle and turn the engine stop switch to RUN.
NOTE: Do not press the throttle while starting the engine.
3. 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 vehicle starts. If the engine does not start, return the keytotheOFF position and wait five seconds before attempting to start again. Activate the starter for another five seconds if necessary. Repeat this procedure until the engine starts.
CAUTION
Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating the vehicle.
Cold Weather Operation
If the ATV is used year-round, check the oil level frequently. A rising oil level could indicate the accumulation of contaminants such as water or excess fuel in t he bottom of the oil tank. Water in the bottom of the tank can lead to engine damage and must be drained. Water accumulation increases as outside temperature decreases.
See your Polaris dealer for engine heater kits, which provide quicker warm-ups and easier starting in colder weather.
49
OPERATION
Driving Safely
Hauling Cargo
1/3
Your ATV has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warning labels on the vehicle, and never exceed the weight capacities outlined in the specifications section of the owner’s manual and on the safety decals.
Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as possible. When operating over rough or hilly terrain, reduce speed and cargo weight to maintain stable driving conditions. Do not obstruct the headlight beam with cargo.
Belt Life
Use low forward gear when hauling or towing heavy cargo to extend belt life.
2/3
50
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 DISTANCES 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 CARRY LOADS 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.
S SECURE ALL LOADS 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 the 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 USE EXTREME CAUTION when operating with loads that
extend over the rack sides. Stability and maneuverability may be adversely affected, causing the vehicle to overturn.
S DO NOT BLOCK THE FRONT HEADLIGHT BEAM when
carrying 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.
51
OPERATION
Driving Safely
Driving Procedures
1. Sit upright with both feet on the footrests and both hands on the handlebars.
2. Start t he 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.
52
OPERATION
Driving Safely
Making Turns
Your ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly. To 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 l eaning 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.
53
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. Engage AWD before wheels begin to lose traction.
3. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns, which can cause skids.
4. Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward.
CAUTION
Severe damage to drive train may occur if the AWD is engaged while the wheels are spinning. Always allow the rear wheels to stop spinning before engaging AWD, or engage AWD before wheels begin to lose traction.
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.
54
OPERATION
Driving Safely
Driving Uphill
25_ Maximum
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.
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.
55
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 the most dangerous type of driving encountered 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
56
downhill, if possible, or dismount on the uphill side immediately!
OPERATION
Driving Safely
Driving Downhill
Whenever descending a hill, follow these precautions:
1. Proceed directly downhill.
2. Transfer your weight to the rear of the vehicle.
3. Slow down.
4. Apply the brakes slightly toaidinslowing. Familiarize yourself with operation of the auxiliary brake in the event
loss of normal service brakes occurs.
WARNING
Excessive speed can cause loss of control and lead to serious injury or death. Always operate slowly when traveling downhill.
57
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 service brake, release the parking brake lock and slowly allow the vehicle to roll around to your right until it’s pointing across the hill or slightly downward.
6. Lock the parking brake and remount the vehicle from the uphill side, keeping body weight uphill.
7. Restart the engine with the transmission still in forward.
8. Release the parking brake and proceed slowly, controlling speed with the service brake, until the vehicle is on more level ground.
58
OPERATION
Driving Safely
Driving Through Water
Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests (1). Follow these procedures when operating through water:
1. Determine water depths and current before crossing.
2. Choose a crossing where both banks have gradual inclines.
3. Proceed slowly, avoiding rocks and obstacles if possible.
4. After crossing, dry the brakes by applying light pressure to the lever until braking action is normal.
After running the vehicle in water, it’s critical to have it serviced as outlined in the maintenance chart. See page 64. The following areas need special attention: engine oil, transmission oil, front gearcase, 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 92. Have the vehicle serviced by your dealer at the first opportunity.
59
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.
60
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: Your Polaris ATV 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.
61
OPERATION
Driving Safely
ParkingonanIncline
Avoid parking on an incline if possible. If it’s unavoidable, follow these precautions:
1. Turn the engine off.
2. Place the transmission in PARK.
3. Set the parking brake.
4. Always block the rear wheels on the downhill side as shown in the illustration.
5. Shut off the fuel supply.
62
EMISSION CONTROL SYSTEMS
Noise Emission Control System
Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements.
Operation on Public Lands in the U.S.A.
Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100-1C. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands.
Operation of off-road vehicles on public lands in the U.S.A. is regulated by 43 CFR 8343. Violations are subject to monetary penalties. Federal regulations can be viewed online at www.gpoaccess.gov/ecfr/.
Crankcase Emission Control System
This engine is equipped with a closed crankcase system. Blow-by gases are forced back to the combustion chamber by the intake system. All exhaust gases exit through the exhaust system.
Exhaust Emission Control System
Exhaust emissions are controlled by engine design. An electronic fuel injection (EFI) system controls fuel delivery. The engine and EFI components are set at the factory for optimal performance and are not adjustable.
Engine idle speed is the only adjustment Polaris recommends that the operator perform. Any other adjustments should be performed by an authorized Polaris dealer.
The emissions label is located on the recoil cover or stator housing.
Electromagnetic Interference
This spark ignition system complies with Canadian ICES-002.
This vehicle complies with European directives 97/24/EC and 89/336/EEC.
63
MAINTENANCE AND LUBRICATION
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 120.
NOTE: Service and adjustments are critical. If you’re not familiar
with safe service and adjustment procedures, have a qualified dealer perform these operations.
Maintenance 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.
64
MAINTENANCE AND LUBRICATION
Periodic Maintenance Chart
Maintenance Chart Key
" Perform these procedures more frequently for vehicles subjected to
severe use.
E Emission-related service (Failure to conduct this maintenance will
not void t he emissions warranty but may affect emissions.)
J Have 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.
65
MAINTENANCE AND LUBRICATION
j
onpage4
8
Periodic Maintenance Chart
Perform all services at whichever maintenance interval is reached first.
Item Maintenance Interval
(whichever comes first)
Hours Calendar Miles
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
E
Coolant -- Daily -- Check level daily, change
Headlamp/tail lamp/worklight
Air filter,
"
main element
E
Recoil housing -- Weekly -- Drain water as needed,
Brake pad wear 10 H Monthly 100 (160) Inspect periodically
" J
Battery 20 H Monthly 200 (320) Check terminals; clean; test
Front gearcase oil 25 H Monthly 250 (400) Inspect level; change yearly
"
Transmission oil 25 H Monthly 250 (400) Inspect level; change yearly
"
Engine breather
"
filter (if equipped)
E
-- Daily -- Drain deposits when visible
-- Daily -- Check operation; apply
-- Weekly -- Inspect; replace as needed
25 H Monthly 250 (400) Inspect; clean if needed
(Km)
Make adjustments as need­ed. See Pre-Ride Checklist on page 48.
as needed
coolant every 2 years
dielectric grease if replacing
check often if operating in wet conditions
Remarks
.
66
MAINTENANCE AND LUBRICATION
Periodic Maintenance Chart
Item Maintenance Interval
(whichever comes first)
Hours Calendar Miles
General
"
lubrication
Throttle Cable/
J
ETC Switch
E
Throttle Body In-
E
take Duct
Drive belt 50 H 6M 500 (800) Inspect; adjust; replace as
Cooling system 50 H 6M 1000 (1600) Inspect coolant strength
Engine oil change 100 H 6M 1000 (1600) Perform a break-in oil
"
Oil filter change 100 H 6M 1000 (1600) Replace with oil change
"
Oil tank vent hose
"
(if equipped)
Valve clearance 100 H 12 M 1000 (1600) Inspect; adjust
J
50 H 3M 500 (800) Lubricate all fittings, pivots,
50 H 6M 500 (800) Inspect; adjust; lubricate;
50 H 6M 500 (800) Inspect duct for proper seal-
100 H 12 M 1000 (1600) Inspect routing, condition
(Km)
cables, etc.
replace if necessary
ing/air leaks
needed
seasonally; pressure test system yearly
change at one month
Remarks
E
Fuel system/filter 100 H 12 M 1000 (1600) Check for leaks at tank cap,
J
E
Radiator
"
(if applicable)
Cooling hoses
"
(if applicable)
Engine mounts 100 H 12 M 1000 (1600) Inspect
"
Exhaust muffler/ pipe
Spark plug 100 H 12 M 1000 (1600) Inspect; replace as needed
J
100 H 12 M 1000 (1600) Inspect; clean external
100 H 12 M 1000 (1600) Inspect for leaks
100 H 12 M 1000 (1600) Inspect
lines, filter, pump; replace lines every two years
surfaces
E
Ignition Timing 100 H 12 M 1000 (1600) Inspect
J
E
Wiring 100 H 12 M 1000 (1600) Inspect for wear, routing,
"
" Perform these procedures more often for vehicles subjected to severe use.
security; apply dielectric grease to connectors subjected to water, mud, etc.
E Emission-Related Service
J Have an authorized Polaris dealer perform these services.
67
MAINTENANCE AND LUBRICATION
Periodic Maintenance Chart
Item Maintenance Interval
(whichever comes first)
Hours Calendar Miles
Clutches (drive
J
and driven)
Front wheel
J
bearings
Brake fluid 200 H 24 M 2000 (3200) Change every two years
J
Spark arrestor 300 H 36 M 3000 (4800) Clean out
Idle speed -- Adjust as needed
Toe adjustment -- Inspect periodically; adjust
J
Headlight aim -- Adjust as needed
" Perform these procedures more often for vehicles subjected to severe use.
100 H 12 M 1000 (1600) Inspect; clean; replace worn
100 H 12 M 1000 (1600) Inspect; replace as needed
(Km)
parts
when parts are replaced
Remarks
E Emission-Related Service
J Have an authorized Polaris dealer perform these services.
68
MAINTENANCE AND LUBRICATION
Lubrication Guide
Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 64. 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 Guide Key
" More often under severe use
L Polaris Premium All Season Grease or grease conforming to NLGI
No. 2, such as Conoco Superlube M or Mobilegrease Special
F Use Polaris Premium U-Joint Lube every 500 miles, before long
periods of storage, or after pressure washing or submerging.
Item Lube Method
Engine Oil Polaris Premium 4 Synthetic
Brake Fluid DOT 3 Only Maintain level between fill
Transmission Oil Polaris Premium AGL Synthetic
Front Demand Drive Unit (Front Gearcase)
Front Prop Shaft Yoke (Fig. 1)
Ball Joint (Fig. 2)
0W40
Gearcase Lube
Premium Demand Drive Hub Fluid
FGrease Grease fittings (3 pumps
"LGrease
Add to proper level on dip­stick.
lines. See page 34.
See page 75.
See page 77.
maximum).
Locate fitting on back side of struts and grease with grease gun.
(Fig. 1)
(Fig. 2)
69
MAINTENANCE AND LUBRICATION
Premium 4 Synthetic Lubricant
Polaris Premium 4 All Season synthetic engine oil has been specially formulated for use in Polaris 4-cycle engines. It’s a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection.
NOTE: See page 107 for the part numbers of Polaris products.
Premium 4 possesses unsurpassed film strength over the widest possible temperature range. It resists viscosity and frictional breakdown in ambient temperatures from -40° F. to 120° F. (-40 to +49° C. ) Its exceptional frictional properties result in more efficient operation, more power output and lower fuel consumption.
Although Polaris Premium 4 is the only oil recommended for use in this engine, use of any API certified SH oil is allowable as long as it’s 0W-40. Oil may need to be changed m ore frequently if Polaris Premium 4 is not used. Follow the manufacturer’s recommendations for ambient temperature operation.
CAUTION
Mixing brands or using a non-recommended oil may cause serious engine damage. We recommend the use of Polaris Premium 4 synthetic Oil or another 0W-40 API certified SH oil. Never substitute or mix oil brands.
70
MAINTENANCE AND LUBRICATION
Oil Level
The oil dipstick and fill tube (1) are located on the left side of the ATV.
NOTE: A rising oil level between checks in cool weather driving can
indicate contaminants such as gas or moisture collecting in the crankcase. If the oil level is over the full/safe mark, change the oil immediately.
1. Position t he ATV on a level surface.
2. Start t he engine and let it idle for 20-30 seconds. Stop the engine.
3. Remove the dipstick and wipe it dry with a clean cloth.
1
4. Reinstall the dipstick completely.
5. Remove the dipstick and check the oil level. Maintain the oil level in the normal or safe range (2). Do not overfill.
ADD 8 OZ. NORMAL FULL
6. Reinstall the dipstick securely.
2
71
MAINTENANCE AND LUBRICATION
Oil and Filter Change
Change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 64.
1. Position t he vehicle on a level surface.Clean the area around the drain plug at the bottom of the oil tank and the bottom of the engine.
2. Run the engine for two to three minutes, then turn it off.
3. Place a drain pan beneath the oil tank and remove the drain plug (1). Allow the oil to drain completely.
4. Install a new sealing washer (2) on the oil drain plug.
NOTE: The sealing surfaces on the drain plug and the oil tank
should be clean and free of burrs, nicks or scratches.
5. Reinstall the drain plug and torque to 14-17 ft. lbs. (19-23 Nm).
6. Disconnect the lower oil delivery hose and remove the screen fitting (3) from the oil tank. Clean the fitting.
NOTE: The fitting threads
must be sealed with LOCTITE PST 505 or PTFE seal tape.
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.
2
1
4
3
NOTE: Do not over-tighten. Maximum torque for the screen fitting is
25 ft. lbs. (34 Nm).
8. Reattach the oil line.
72
MAINTENANCE AND LUBRICATION
Oil Change
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.
NOTE: Thesealingsurfaceson
the drain plug and crankcase should be clean and free of burrs, nicks or scratches.
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. Pl ace the gear selector in neutral and set the parking brake.
16. Prime the oil pump using the procedure on page 74. Then stop the engine and inspect for leaks.
17. Recheck the oil level on t he dipstick and add oil as necessary to bring it to the recommended level on the dipstick.
18. Dispose of used filter and oil properly.
2
1
73
MAINTENANCE AND LUBRICATION
Oil Change
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 t he 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 i s 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.
2I
2
1
3
74
MAINTENANCE AND LUBRICATION
Transmission Oil
Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 64. We recommend the use of Polaris P remium AGL Synthetic Gearcase Lubricant. See page 107 for the part numbers of Polaris products.
Oil Check
On the Sportsman 400 and 500, the transmission fill plug (1) is located on the left side of the ATV, under the rear fender, behind the wheel.
1
1. Position t he ATV on a level surface and remove the fill plug.
2. Add t he recommended oil as needed to bring the level to the bottom of the fill plug hole threads.
3. Reinstall the fill plug. Torque to 22 ft. lbs. (30 Nm).
75
MAINTENANCE AND LUBRICATION
Transmission Oil
Oil Change
The transmission drain plug (2) is located on the right side of the gearcase, on the right side of the ATV, behind the wheel well.
2
2
1. Remove the fill plug and the transmission drain plug.
2. Drain the oil into a drain pan and dispose of properly.
3. Clean and reinstall the drain plug. Torque to 22 ft. lbs. (30 Nm).
4. Add 32 oz. (948 ml) of the recommended transmission oil to bring the level to the bottom of the fill plug.
5. Reinstall the fill plug. Torque to 22 ft. lbs. (30 Nm).
6. Check for leaks.
76
MAINTENANCE AND LUBRICATION
Front Gearcase Oil
Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 66. Maintain the oil level even with the bottom of the fill hole threads (1). We recommend the use of Polaris Premium Demand Drive Hub Fluid. Use of other oils may result in improper operation of components. See page 107 for the part numbers of Polaris products.
Oil Check
1. Position t he ATV on a level surface.
2. Remove the fill plug (2) and view the oil level.
3. Add the recommended gearcase oil as needed to bring the level to the bottom of the fill hole threads.
4. Reinstall the fill plug. Torque to 8-10 ft. lbs. (11-14 Nm).
Oil Change
1. Position t he vehicle on a level surface and remove the fill plug.
2. Place a drain pan beneath the gearcase, remove the gearcase drain plug (3) located on the bottom right-hand side, and drain the oil.
3. Clean and reinstall the drain plug. Torque to 11 ft. lbs. (15 Nm).
4. Add 5 ounces (150 ml) of Polaris
Premium Demand Drive Hub Fluid.
5. Reinstall the fill plug. Torque to 8-10 ft. lbs. (11-14 Nm).
6. Check for leaks.
1
3
2
77
MAINTENANCE AND LUBRICATION
Engine Cooling System
Radiator Coolant Level
To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added. Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. See page 107 for the part numbers of Polaris products.
NOTE: Always follow the manufacturer’s mixing recommendations
for the freeze protection required in your area.
Any time the cooling system has been drained for maintenance or repair, replace the coolant. If the recovery bottle has run dry, the level in the radiator should be inspected. Add coolant as needed.
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.
1. To access the radiator pressure cap, open the front box lid and pull open the access door.
2. Remove the pressure cap (1).
3. Using a funnel, slowly add coolant through the radiator filler neck.
4. Reinstall the pressure cap, secure the access door and close the box.
1
NOTE: Use of a non-standard pressure cap will not allow the
78
recovery system to function properly. Contact your dealer for the correct replacement part.
MAINTENANCE AND LUBRICATION
Engine Cooling System
Coolant Level
The recovery bottle (1) is located on the left side of the machine. To access the recovery bottle, remove the left side panel as outlined on page 83.
Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool). Add coolant as needed.
Cooling System Operation
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.
1
NOTE: Some coolant level drop on new machines is normal, as the
system is purging itself of trapped air. Observe coolant levels and maintain as recommended by adding coolant to the recovery bottle.
79
MAINTENANCE AND LUBRICATION
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.
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 keep brake fluid at an adequate level (see page 34).
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
80
reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced. Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation. Use Polaris DOT 3 brake fluid. Do not overfill.
MAINTENANCE AND LUBRICATION
Brakes
2. Check the brake system for fluid leaks.
3. Check the brakes for excessive travel or spongy feel.
4. Check the friction pads for wear, damage and looseness.
5. Check the security and surface condition of the disc.
NOTE: Pads should be changed
when worn to 3/64(.1 cm).
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.
81
MAINTENANCE AND LUBRICATION
Steering Assembly
The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle.
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 t he vehicle. The recommended toe alignment is 1/8to 1/4toe out.
1. Set the handlebars in a straight-ahead position.
NOTE: Thesteeringfrogcan
be used as an indicator of whether the handlebars are straight. The frog should always point straight back from the steering post.
2
2. Place stands (1) in front of the vehicle, perpendicular to the rear tires. See illustration.
3
3. Tie an elastic string around the stands, making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in
1
front of the vehicle (2).
4. Measure the distance from the string to the rim at the front and rear of the front rim (3). Rear measurement should be 1/16-1/8″ (.2 to .3 cm) more than the front measurement.
NOTE: If you discover improper alignment, see your Polaris dealer
for service.
82
MAINTENANCE AND LUBRICATION
Side Panel Removal
1. Remove the seat.
2. Grasp the rear of the side panel near the rear cab. With a firm motion, pull the panel outward to disengage the side panel from the grommet.
3. Pull the panel downward and rearward to remove it from the ATV.
4. Reinstall the side panel by reversing the removal procedure.
3
1
Footwell Removal
1. Remove the four screws (1) on the bottom of the footwell.
2. Use a flat screwdriver or sidecutters to remove the plastic rivets (2) securing the footwell to the fenders.
3. Remove the footwell.
2
3
2
1
83
MAINTENANCE AND LUBRICATION
WARNING
Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death.
Maintain proper tire pressure as described on the decal on your ATV and in the 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.
Tire Tread Depth
Always replace tires when tread depth is worn to 1/8(.3 cm) or less. See illustration.
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.
1/8I (.3 cm)
Wheel Removal
1. Stop the engine, place the transmission in PARK 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.
84
MAINTENANCE AND LUBRICATION
Wheel Installation
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.
1. Place the transmission in PARK and lock the parking brake.
2. Place the wheel on the wheel hub with the valve stem toward the outside and the rotation arrows on the tire pointing toward forward rotation.
3. Install the wheel nuts and finger tighten.
4. Lower the vehicle to the ground.
5. Torque the wheel nuts t o specification.
1
90 ft. lbs. (122 Nm)
Cast Aluminum Steel
27 ft. lbs. (37 Nm)
Wheel Nut Torque Specifications
Check the wheel nut torques occasionally and when they’ve been loosened for maintenance service.
Nut Type Nut Torque
1. Lug Nut 90 ft. lbs. (122 Nm)
2. 2-Piece Flange Nut 27 ft. lbs. (37 Nm)
2
85
MAINTENANCE AND LUBRICATION
Filter Systems
Air Filter Service
1. Remove the seat, release the air box cover 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 in 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 into the air box and tighten the clamp. Do not over tighten the clamp, as filter damage could occur.
6. Reinstall the air box cover and the seat.
Breather Filter/Hose
1. To access the breather filter (3), remove the left side panel as outlined on page 83. The breather filter is on the hose that runs between the engine and air box.
2. Remove the clamps and pull the filter out of the hoses.
1
2
3
NOTE: It’s not necessary to remove the lower hose from the engine.
3. Inspect the filter for debris. Blow gently through the filter in the direction of the arrow to check for clogging. Replace if needed.
4. Check the hoses for cracks, deterioration, abrasion, or leaks. Replace as needed.
5. Reinstall the filter and secure the clamps.
NOTE: The filter is effective with the arrow pointing in either
direction.
CAUTION
Operation of your vehicle without a breather filter can cause engine damage. Always reinstall the breather filter after removing for service.
86
MAINTENANCE AND LUBRICATION
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. Allow lamps to cool before servicing.
Headlight Lamp Replacement
1. Remove the two screws on the lower front corners of the headlight pod.
2. Remove the screw from the rear of the pod.
3. Lift the pod slightly while depressing the tabs at the rear of the pod.
4. Lift the pod cover and disconnect the speedometer harnesses from the speedometer.
5. Unplug the headlamp from the wiring harness. Be sure to pull on the connector, not on the wiring.
6. Turn the lamp counterclockwise to remove it.
7. Apply dielectric grease to the socket and install the new lamp.
NOTE: Make sure the tab on the lamp locates properly in the
housing.
8. Reassemble the pod.
87
MAINTENANCE AND LUBRICATION
Lights
High Beam Adjustment
The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment.
1. Position t he vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a 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 two inches (5.1 cm) below the mark on the wall.
NOTE: Include rider weight on the seat when measuring.
5. The adjustment knob is located on the right side of the headlight pod. Adjust the beam to the desired position by turning the knob either clockwise or counterclockwise.
Low Beam Adju stment
The low beam can be adjusted slightly upward or downward.
1. Loosen the phillips screw (1) located at the rear of the headlamp.
2. Tilt the headlamp upward or downward.
3. Tighten the screw.
1
88
MAINTENANCE AND LUBRICATION
Lights
Headlight Housing Replacement
1. Remove the two screws on the lower front corners of the headlight pod.
2. Lift the pod slightly while depressing the tabs at the rear of the pod.
3. Lift the pod cover and disconnect the speedometer harnesses from the speedometer.
4. Unplug the headlamp from the wiring harness.
5. Use a small screwdriver to remove the o-rings from the headlight mounting t abs.
6. Pull the headlight housing up to release it from the locking tabs.
7. Lift the adjusting knob up to remove it from t he locking tabs.
8. Carefully pull the assembly up and out of the pod.
9. Reverse the steps to install the new housing and reassemble the pod.
NOTE: The distance from the
headlamp parting line to the end of the adjustment knob stop is 5 1/8(13 cm).
10. Adjust the headlight aim by turning the adjusting knob.
51/8 (13 cm)
89
MAINTENANCE AND LUBRICATION
Lights
Lower Headlamp Removal / Installation
1. Turn the back of the headlight harness (1) counterclockwise and pull the harness assembly away from the headlight assembly.
2. Remove the headlamp and install the new headlamp.
3. Reinstall the harness assembly into the headlight assembly.
4. Turn the headlight harness clockwise to secure the headlamp.
Taillig h t /Brakelight/Worklight Lamp Replacement
1. Remove the harness connector (1) from the back of the light assembly.
2. Turn the l amp (2) counterclockwise to remove it.
3. Apply dielectric grease to the socket and install the new lamp.
4. Reinstall the harness connector.
5. Test the light for proper operation.
1
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1
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MAINTENANCE AND LUBRICATION
Spark Plugs
Always use the spark plugs recommended for your ATV. Refer to the specifications section beginning on page 112 for the recommended spark plug type and gap.
CAUTION
Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs.
Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color.
WARNING
A hot exhaust system and engine can cause serious burns. Wear protective gloves when removing a spark plug for inspection.
1. Normal
The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service.
NOTE: The tip should not be white. A white insulator tip indicates
overheating, caused by use of an improper spark plug or incorrect fuel.
2. Wet Fouled
The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. General causes of fouling are excessive oil, use of non-recommended oil, or incorrect throttle body adjustments.
Spark Plug Removal and Replacement
1. Remove the spark plug cap.
2. Using the special wrench provided in the tool pouch, rotate the spark plug counterclockwise to remove.
3. Reverse the procedure for spark plug installation, using the recommended spark plug. Torque to 18 ft. lbs. (24 Nm).
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MAINTENANCE AND LUBRICATION
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 ATV to a dealer before starting it, follow the steps outlined below.
1. Move the ATV to dry land or at the very least, to water below the footrests.
2. Check the air box for any water and dry it if water is present.
NOTE: Filter replacement is required if water is present.
3. Remove the spark plug.
4. Turn the engine over several times using the electric start.
5. Dry the spark plug and reinstall, or replace it with a new plug.
6. Attempt to start the engine. If necessary, repeat the drying procedure.
7. Take the ATV to your dealer for service as soon as possible, whether you succeed in starting it or not.
NOTE: If water has been ingested into the PVT, follow the procedure
on page 95 for drying out the PVT.
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MAINTENANCE AND LUBRICATION
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 PARK 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 t he front. Set the parking brake and block the wheels. Make sure the vehicle is in PARK 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.
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MAINTENANCE AND LUBRICATION
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 appliedtothe drive belt. Similarly, if the engine speed decreases, the amount of centrifugal force decreases, reducing the amount of belt pinch.
On Polaris ATVs, the approximate gear ratio difference between high and low range is 1:2.25. This difference in gearing affects the operation of the PVT, especially at speeds less than 7 MPH (11 KPH), due to the system’s dependence on engine speed.
For example, when operating at a ground speed of 3 MPH (5 KPH) in low range, the engine speed would be around 3000 RPM. This is well above the engagement speed of 1200 - 1400 RPM. However, in high range at 3 MPH (5 KPH), the engine would be running at only 1500 RPM. Whenever operating this close to the engagement speed, the engine may be running at a speed too low to provide the pinch needed to prevent belt slip. Belt slip is responsible for creating the excessive heat that destroys belts and causes outer clutch covers to fail.
By switching to low range while operating at low ground speeds, the air temperature in the clutch cover is reduced by almost 160 degrees. Reducing the temperature inside the clutch cover extends the life of the PVT components (belt, cover, etc.).
When To Use Low Range vs. High Range
Following is a guideline for when to use low range and high range.
Low Range
S When basic operation is at speeds less than 7 MPH (11 KPH) S For heavy pulling S When operating in rough terrain (swamps, mountains, etc.) at low
ground speeds
High Range
S When basic operation is at speeds greater than 7 MPH (11 KPH) S When operating at high ground speeds
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MAINTENANCE AND LUBRICATION
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. Replace 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.
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MAINTENANCE AND LUBRICATION
Battery
Your ATV 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 t he 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. V entilate when charging or using in an enclosed space. Always shield eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN.
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MAINTENANCE AND LUBRICATION
Battery
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 ATV. 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.
Battery Installation
1. Set t he battery in the battery holder.
2. 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. If not, battery gases could accumulate and cause an explosion. The tube should be routed away from the frame and body to prevent corrosion. Avoid skin contact with electrolyte, which can cause severe burns.
3. First connect and tighten the red (positive) cable.
4. Second connect and tighten the black (negative) cable.
5. Reinstall the battery cover and attach the hold-down strap.
6. Verify that cables are properly routed.
NOTE: When installing a new battery, make sure it’s fully charged
prior to its initial use. 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.
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