Polaris Sportsman 9921477 User Manual

Page 1

WELCOME

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

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER utility vehicles

• Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recre-

ational 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.co m. Have your accessories and clothing delivered right to your door!

Page 2

POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc.

Copyright 2007 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or in acc uracies. 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. 2008 Sportsman 500 EFI Owner’s Manual P/N 9921477

Page 3

TABLE OF CONTENTS

Know Your Vehicle . . . . . . . . . . . . . . . . . . . . . . . 5

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Features and Controls . . . . . . . . . . . . . . . . . . . 34

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Emission Control Systems . . . . . . . . . . . . . . . 73

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 129

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 133

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 134

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 142

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

Page 4

Page 5

KNOW YOUR VEHICLE

####

VIN

Engine Serial Number

Key Number

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.

Vehicle Identification Numbers

Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a Polaris key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost.

Vehicle Model Number: ___________________________________________________

Frame VIN: _____________________________________________________________

Engine Serial Number: ____________________________________________________

Key Number: ___________________________________________________________

Page 6

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.

General Warning

WARNING Improper ATV use can result in SEVERE INJURY

or DEATH

ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR

NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate:

• without proper training or instruction

• at speeds too fast for your skills or the conditions

• on public roads - a collision can occur with another vehicle

• with a passenger - passengers affect balance and steering and increase risk of losing control

ALWAYS:

• use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns

• avoid paved surfaces - pavement may seriously affect handling and control

LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. IF OWNER’S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A

REPLACEMENT.

Page 7

SAFETY

Tire Pressure/Load

Warning

Discretionary

Warning

Safety Decals and Locations

Discretionary Warning

WARNING

• Never operate this ATV on HILLS steeper than 25 degrees 25°. To p re -

vent flip-over on hilly terrain, when going up or down, use throttle and brakes gradually.

• REVERSE operation can be dangerous even at low speeds. Steering

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

• Use OVERRIDE for reverse speed limiter with caution. To prevent loss of

control, never activate override button with open throttle.

• When this ATV is not in operation, or unattended, place shift in the park posi-

tion.

Tire Pressure/Load Warning

WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause 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 485 LBS. (220 KG) INCLUDES WEIGHT OF OPERATOR, CARGO AND ACCESSORIES Reduce speed and allow greater distance for braking when carrying cargo.

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

Read Owner's Manual for more detailed loading information

Page 8

SAFETY

“No Passenger”

Warning

Clutch Cover

Warning

Age 16 Warning

Rack

Warning

Rack

Warning

Safety Decals and Locations

“No Passenger” Warning

WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or

DEATH.

Age 16 Warning

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.

Page 9

SAFETY

Safety Decals and Locations

Clutch Cover Warning

WARNING NO STEP

• Moving parts hazard under belt-clutch guard. To prevent serious injury, do not

operate vehicle with guard removed.

• 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.

Rack Warning, Front and Rear

WARNING

• DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may

result causing severe injury or death. Tow only from tow hooks or hitch.

• Max Rack Loads: Front 90 lbs. (41 kg) Rear 180 lbs. (82 kg)

Reverse Override Warning

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 4X4 (AWD). See Owner's Manual.

Hitch Capacity Label

TRAILER MAX WEIGHT: 1225 LBS. (557 KG) ON LEVEL GROUND 850 LBS. (386 KG) UP TO 15° GRADE HITCH MAX. VERTICAL WEIGHT: 120 LBS. (55 KG)

Page 10

SAFETY

Helmet

Eye Protection

Gloves

Boots

Long Pants

Long

Sleeves

051039

0006.31

Safe Riding Gear

Always wear appropriate clothing when riding an ATV. Wear protective clothing for comfort and to reduce the chance of injury.

Helmet

Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards.

Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.

Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. The ECE mark consists of a circle surrounding the letter E, followed by the distinguishing number of the country which has granted approval. The approval number and serial number will also be displayed on the label.

Page 11

SAFETY

Safe Riding Gear

Eye Protection

Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.

Gloves

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

Boots

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

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.

Page 12

SAFETY

Operator Safety

WARNING

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

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

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

Age Restrictions

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

Page 13

SAFETY

Operator Safety

Safety Training

ATV safety training is a top priority for Polaris. When you purchased your new ATV, your dealer instructed you on the authorized ATV

RiderCoursesm available to you and your eligible family members. This

training is included in the purchase price of your ATV. Polaris strongly encourages you and your eligible family members who will be riding the ATV to take the ATV RiderCourse printed materials that explain safe operating procedures. You should review this information on a regular basis.

If you purchased a used Polaris ATV, you can take the ATV

RiderCourse

by calling A TV Enrollment Express at (800) 887-2887 or by visiting www.atvsafety.org. Purchasers of a used Polaris ATV will be charged for this training.

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

W e 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.

. You were also provided with

Page 14

SAFETY

Operator Safety

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

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

Page 15

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.

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

procedures described.

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

course. Purchasers of a new Polaris ATV and their eligible family members are entitled to take the ATV RiderCourse Enrollment Express at (800) 887-2887 or visit www.atvsafety.org for information on enrollment in the ATV RiderCoursesm.

• Never allow anyone under 16 years of age to operate this ATV.

• Never permit a guest to operate the A TV unless the guest has read this

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

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

walks, driveways, parking lots, and streets.

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

dirt or gravel road.

• 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.

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

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

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

• Never attempt wheelies, jumps or other stunts.

• 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.

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

rests of the ATV during operation.

. Contact ATV

Page 16

SAFETY

Operator Safety

• Always travel slowly and use extra caution when operating on unfamiliar terrain. Be alert to changing terrain conditions.

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

• Always follow proper turning procedures as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speeds.

• Always have the ATV inspected by an authorized Polaris dealer if it's been involved in an accident.

• Never operate on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills.

• Always follow proper procedures for climbing hills. Check the terrain carefully before ascending a hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight uphill. Never open the throttle suddenly or make sudden gear changes. Never go over the top of a hill at high speed. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.

• 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 uphill. 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. Drive straight downhill. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.

• Always follow proper procedures for crossing the side of a hill. A void hills with excessively slippery or loose surfaces. Shift your weight uphill. Never attempt to turn the ATV around on any hill until you've mastered (on level ground) the turning technique outlined in this manual. Avoid crossing the side of a steep hill when possible.

• 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.

Page 17

SAFETY

Operator Safety

• 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.

• 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.

• 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.

• 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.

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

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

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

always maintain proper tire pressure.

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

sories.

• 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.

Page 18

SAFETY

Operator Safety

FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety Commission at 1-800-638-2772, or visit www.cpsc.gov, visit www.atvsafety.org, 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) mow-

ers, 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.

Page 19

Operator Safety

WARNING

POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the

operator does not know how to operate the ATV properly in different situations and on different types of terrain.

HOW TO AVOID THE HAZARD Beginning and inexperienced operators should

complete the ATV RiderCourse Polaris through the SVIA. They should then regularly practice the skills learned in the course and the operating techniques described in the Owner's Manual.

For more information about the ATV RiderCourse Express at (800) 887-2887 or visit www.atvsafety.org.

offered by

contact ATV Enrollment

WARNING

POTENTIAL HAZARD Failure to follow the age recommendations for

this ATV. WHAT CAN HAPPEN Severe injury and/or death could occur if a child

under the minimum age recommendation operates an 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 HAZARD No one under the age of 16 should operate a Polaris ATV.

SAFETY

Page 20

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Carrying a passenger on an ATV. WHAT CAN HAPPEN Carrying a passenger greatly reduces the

operator's ability to balance and control the ATV, which could cause an accident and injury to the operator and/or passenger.

HOW TO AVOID THE HAZARD Never carry a passenger. The purpose of the

long seat is to allow the operator to shift position as needed during operation. It is not intended for carrying passengers.

WARNING

POTENTIAL HAZARD Operating an ATV on paved surfaces, including

sidewalks, paths, parking lots, and driveways. WHAT CAN HAPPEN ATV tires are designed for off-road use.

Operating on paved surfaces may adversely affect the handling of the ATV and could result in loss of control, accident, and/or injury.

HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement. If it's

unavoidable, travel slowly and avoid sudden turns or stops.

Page 21

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Operating this ATV on public streets, roads or

highways. WHAT CAN HAPPEN The ATV could collide with another vehicle. HOW TO AVOID THE HAZARD Never operate the ATV on any public street,

road or highway, including dirt and gravel roads. In many states it's illegal to operate ATVs on public streets, roads and highways.

WARNING

POTENTIAL HAZARD Operating this ATV without wearing an

approved helmet, eye protection and protective clothing.

WHAT CAN HAPPEN Operating an ATV without an approved helmet

increases the risk of a severe head injury or death in the event of an accident.

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

HOW TO AVOID THE HAZARD Always wear an approved helmet that fits properly. Always wear eye protection (goggles or face shield), gloves, boots, long-

sleeved shirt or jacket, and long pants.

Page 22

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Operating the ATV after consuming alcohol or

drugs. WHAT CAN HAPPEN Consumption of alcohol and/or drugs could

seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected.

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

HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while operating an ATV.

WARNING

POTENTIAL HAZARD Operating the ATV at excessive speeds. WHAT CAN HAPPEN Excessive speed increases the operator's

chance of losing control of the ATV, which can result in an accident causing severe injury or death.

HOW TO AVOID THE HAZARD Always operate the ATV at a speed that's

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

Page 23

Operator Safety

WARNING

POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Attempting stunts increases the chance of an

accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt wheelies, jumps, or other stunts.

Avoid exhibition driving.

WARNING

POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Poor maintenance increases the possibility of

an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV before each use to

make sure it's in safe operating condition. Always follow the inspection and maintenance

procedures and schedules described in the owner's manual.

SAFETY

Page 24

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Removing hands from the handlebars or feet

from the footrests during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce

ability to control the vehicle or could cause loss of balance and ejection from the ATV.

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

HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of

the ATV during operation.

WARNING

POTENTIAL HAZARD Failure to use extra caution when operating the

ATV on unfamiliar terrain. WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks,

bumps, or holes that could cause loss of control or overturn.

HOW TO AVOID THE HAZARD Travel slowly and use extra caution when

operating on unfamiliar terrain. Always be alert to changing terrain conditions.

Page 25

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Failure to use extra caution when

operating on excessively rough, slippery or loose terrain.

WHAT CAN HAPPEN Operating on excessively rough,

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

HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you've

learned and practiced the skills necessary to control the ATV on such terrain. Always use extra caution on rough, slippery or loose terrain.

WARNING

POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN Improper turns could cause loss of control and

lead to a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as

described in the owner's manual. Practice turning at slow speeds before

attempting to turn at faster speeds. Never turn at excessive speed.

Page 26

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle may overturn. HOW TO AVOID THE HAZARD Never operate on hills too steep for the ATV or

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

WARNING

POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner's

manual. See page 65. Always move the 4X4 switch to ADC 4X4 before ascending or descending a

hill. See page 46. Always check the terrain carefully before ascending any hill. Never operate the ATV on hills steeper than 25 degrees. 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.

Page 27

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Traveling downhill improperly. WHAT CAN HAPPEN Improperly descending a hill could

cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for

traveling down hills as described in the owner's manual. NOTE: A special technique is required when braking while traveling downhill. See page 67.

Always descend a hill with the transmission in forward gear. Do not descend a hill with the transmission in neutral. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 46.

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

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

WARNING

POTENTIAL HAZARD Improperly crossing hills and turning on hills. WHAT CAN HAPPEN Improperly crossing or turning on hills could

cause loss of control or overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any

hill until you've mastered the turning technique (on level ground) as described in the owner's manual. See page 68. Use extra caution when turning on any hill.

Avoid crossing the side of a steep hill. When crossing the side of a hill: Always follow proper procedures as described in the owner's manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.

Page 28

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Stalling, rolling backwards or improperly

dismounting while climbing a hill. WHAT CAN HAPPEN The vehicle could overturn. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. Always move the 4X4 switch to ADC 4X4 before

ascending or descending a hill. See page 46.

If all forward speed is lost:

Keep your weight uphill. Apply the brakes. Lock the parking brake when fully stopped.

If the ATV begins rolling backwards:

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 68.

Page 29

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees when

possible. If unavoidable, use extreme caution and always follow proper procedures as outlined in the owner's manual.

WARNING

POTENTIAL HAZARD Skidding or sliding. WHAT CAN HAPPEN Skidding or sliding can cause loss of control. If the tires regain traction unexpectedly, the ATV could overturn. HOW TO AVOID THE HAZARD On slippery surfaces such as ice, travel slowly and use extra caution to

reduce the chance of skidding or sliding out of control.

Page 30

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Operating the ATV through deep or

fast-flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction

and loss of control, which could lead to an accident or overturn.

HOW TO AVOID THE HAZARD Avoid operating the ATV through deep

or fast-flowing water. If it's unavoidable to enter water that exceeds the recommended maximum depth (see page 69), 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.

WARNING

POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN The ATV could collide with an obstacle or person, resulting in severe injury. HOW TO AVOID THE HAZARD Before shifting into reverse gear, always check for obstacles or people

behind the ATV. When it's safe to proceed, back slowly.

Page 31

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Operating this ATV with improper tires,

or with improper or uneven tire pressure.

WHAT CAN HAPPEN Use of improper tires, or operation of

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

HOW TO AVOID THE HAZARD Always use the size and type of tires

specified for the ATV in the owner's manual. Always maintain proper tire pressure as described in the owner's manual and

on safety decals.

WARNING

POTENTIAL HAZARD Operating the ATV with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of the ATV may cause

changes in handling, which could lead to an accident. HOW TO AVOID THE HAZARD Never modify the ATV through improper installation or use of accessories. All

parts and accessories added to the vehicle must be genuine Polaris Industries Inc. or equivalent components designed for use on this ATV and should be installed and used according to approved instructions. See your authorized Polaris ATV dealer for more information.

Page 32

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Overloading the ATV or carrying/towing cargo improperly. WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling, which could

lead to loss of control or an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow a greater

distance for braking. Always follow the instructions in the owner's manual for carrying cargo or

pulling a trailer.

WARNING

POTENTIAL HAZARD Operating on frozen bodies of water. WHAT CAN HAPPEN Severe injury or death can result if the ATV and/or the operator fall through

the ice. HOW TO AVOID THE HAZARD Never operate the ATV on a frozen body of water.

Page 33

SAFETY

Operator Safety

WARNING

Operating a damaged ATV can result in an accident with serious injury or death. After any overturn or accident, have a qualified service dealer inspect the entire machine 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.

WARNING

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.

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.

Page 34

FEATURES AND CONTROLS

Mode/Reverse

Override

Switch

Work Light

Switch

(if equipped)

Main Key Switch

Engine

Stop Switch

Headlight

Switch

4X4

Switch

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.

Mode/Reverse Override Switch

This vehicle is equipped with a reverse speed limiter system.To gain additional power while backing, depress the override switch.

NOTE: The override switch also allows activation of 4X4 in reverse, if the 4X4

switch is on. This switch is also used to toggle through the modes of the rider information center. See page 47.

4X4 Switch

Use the 4X4 switch to engage ADC 4X4, 4X4 or 2X4. See page 46.

Page 35

FEATURES AND CONTROLS

OFF OFFRUN

Switches

Engine Stop Switch

Move the stop switch either left or right to the OFF position to stop the engine quickly. The engine will not start or run when the switch is off.

NOTE: Both the main switch and the engine stop switch will shut off all electri-

Main Key Switch

Use the main key switch to start the engine. See page 59 for starting procedures.

Work Light Switch

Use the work light switch (if equipped) to turn the work light on or off. The work light is located at the rear of the vehicle. Turn the light on while loading and unloading cargo in low light situations. Turn the work light off when driving.

Headlight Switch

Use the headlight switch to turn the lights on and off and to change the lights from high beam to low beam.

NOTE: The lights won't work unless the key is in the ON position and the

cal power to the vehicle, including lights.

engine stop 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.

Page 36

FEATURES AND CONTROLS

Throttle Lever

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.

Engine speed and vehicle movement are controlled by pressing the throttle lever. 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.

WARNING

Modifications to the ETC could result in failure to perform as designed, which could result in severe injury or death. Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms. Always ensure that the throttle cable is properly installed to the ETC.

Page 37

FEATURES AND CONTROLS

Brake Lever

Squeeze the brake lever toward the handlebar to apply the front and rear brakes. These 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.

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.

Page 38

FEATURES AND CONTROLS

Master Cylinder

Indicator

Window

Master Cylinder/Brake Fluid

Check the brake fluid in the master cylinder before each ride. The fluid level can be seen through an indicator window on the top of the master cylinder. This eye will appear dark when the fluid level is full. When fluid is low, the eye will be clear.

NOTE: When checking the fluid

If the fluid level is low add DOT 4 brake fluid only. See page 133 for the part numbers of Polaris products.

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.

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.

level, the ATV must be on level ground with the handlebars straight.

WARNING

Page 39

FEATURES AND 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.

Locking the Parking Brake

1. Place the transmission in

PARK.

2. Squeeze and release the brake

lever two or three times, then squeeze and hold.

3. Push the parking brake lock

forward to engage the lock.

4. Release the brake lever.

5. To release the parking brake lock, squeeze and release the brake

lever. It will return to its unlocked position.

Important Safeguards

• The parking brake may relax if left on for a long period of time.

Always block the wheels to prevent rolling.

• Always block the wheels on the downhill side of the A TV if leaving it

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

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

hill. Always block the wheels to prevent rolling.

Page 40

FEATURES AND CONTROLS

Auxiliary Foot Brake

The auxiliary brake system is intended to be used as a backup for the main brake system. Should the main system fail, use the auxiliary foot brake.

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

Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death. Never back down a hill.

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

The auxiliary foot brake is located on the inside of the right footrest. Operate this brake with your right foot.

NOTE: If the rear wheels slide while

Brake Fluid Level

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

single lever system.

WARNING

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

Page 41

FEATURES AND CONTROLS

Fuel

Ta n k

Cap

Fuel Tank Cap

Remove the fuel tank cap to add fuel to the fuel tank. Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. Do not use E-85 fuel.

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.

Page 42

FEATURES AND CONTROLS

Gear

Selector

Automatic Transmission Gear Selector

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

H: High Gear L: Low Gear N: Neutral R: Reverse P: Park

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

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.

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.

Page 43

FEATURES AND CONTROLS

Recoil Starter

Handle

Recoil Starter

If the battery is too weak to start the engine, use the recoil starter. Follow the starting procedures on page 59, cranking the engine with the recoil starter instead of the main key switch.

1. Grasp the recoil starter rope

handle tightly.

2. Pull slowly so you can feel

the engine strokes.

NOTE: The rope will be harder to pull when the engine is on a compression

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

4. Repeat all steps until the engine starts.

5. Make sure the handle is fully seated on the housing.

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

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

stroke. When a compression stroke is found, continue pulling the rope just until the engine rolls past the stroke, then stop pulling immediately.

the rope abruptly and forcefully to start the engine.

CAUTION

Page 44

FEATURES AND CONTROLS

4X4

Switch

All Wheel Drive System

The All Wheel Drive system is controlled by the 4X4 switch.

ADC 4X4 Mode

When the switch is on ADC 4X4, the ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 46.

4X4 Mode

When the switch is on 4X4, the ATV is in 4X4, and the 4X4 indicator light in the instrument cluster will be on.

When in 4X4, the demand drive unit will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the demand drive unit will automatically disengage. There is no limit to the length of time the vehicle may remain in 4X4.

NOTE: The override switch allows activation of 4X4 in reverse if the 4X4

2X4 Mode

When the switch is on 2X4, the ATV is in two-wheel drive at all times.

switch is on. See page 34.

Page 45

FEATURES AND CONTROLS

All Wheel Drive System

Engaging 4X4

The 4X4 switch may be turned on or off while the vehicle is moving. Initially, the vehicle's electronic system will not enable 4X4 until the engine RPM is below 3100. Once enabled, 4X4 remains enabled until the 4X4 switch is turned off. If the switch is turned of f while the demand drive unit is moving, it will not disengage until the rear wheels regain traction.

Engage the 4X4 switch before getting into conditions where front wheel drive may be needed. If the rear wheels are spinning, release the throttle before switching to 4X4.

CAUTION

Switching to 4X4 or ADC 4X4 while the rear wheels are spinning may cause severe drive shaft and gearcase damage. Always switch to 4X4 or ADC 4X4 while the rear wheels have traction or are at rest.

Page 46

FEATURES AND CONTROLS

Active Descent Control (ADC) System

The ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.

Engaging Active Descent Control

The ADC system will automatically engage when all four of the following conditions occur:

• The 4X4 switch must be in the ADC 4X4 position

• Vehicle speed must be 15 mph (24 km/h) or less

• The throttle must be closed (throttle lever released)

• The transmission must be in gear (high, low or reverse)

Disengaging Active Descent Control

The ADC system will automatically disengage if at least one of the following conditions occur:

• The 4X4 switch is moved out of the ADC 4X4 position

• Vehicle spe ed exc eeds 15 mph (24 km/h)

• The throttle is open (throttle is applied)

• The transmission is shifted to neutral or park

Page 47

FEATURES AND CONTROLS

Rider

Information

Center

Speedometer

Needle

Speedometer

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 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 34 for additional information.

NOTE: In addition to showing vehicle speed, the speedometer needle flashes

High water pressure may damage ATV components. Wash the ATV by hand or with a garden hose using mild soap.

Certain products, including insect repellents and chemicals, will damage the speedometer lens and other plastic surfaces. Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens. Immediately clean off any gasoline that splashes on the instrument cluster.

when a warning condition exists.

CAUTION

Page 48

FEATURES AND CONTROLS

345

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

1. Gear Indicator - This

2. 4X4 Indicator - This

3. Engine Hour Display Indicator

4. Service Interval/Diagnostic Mode Indicator

5. Low Battery and Over Voltage - This warning usually indicates

6. Odometer/Tachometer/Tripmeter/ Hour Meter/Clock

7. Fuel Gauge - The segments of the fuel gauge show the level of fuel

8. Check Engine Warning Indicator - This indicator serves two pur-

9. Mode Indicator

have occurred and the instrument cluster may have shut off to protect the electronic speedometer. If this occurs, take the ATV to your Polaris dealer for proper diagnosis.

indicator displays gear shifter position: H = High Gear L = Low Gear N = Neutral R = Reverse Gear P = Park

indicator illuminates when the 4X4 switch is on either ADC 4X4 or 4X4.

that the ATV is operating at an RPM too low to keep the battery charged. It may also occur when the engine is at idle and high electrical load (lights, cooling fan, accessories) is applied. Drive at a higher RPM or recharge the battery to clear the warning.

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.

poses. The word HOT displays if the engine overheats. It also appears if an EFI-related fault occurs. Do not operate the ATV if this warning appears. Serious engine damage could result.

Page 49

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Standard Modes

Use the MODE button to toggle through the mode options. The reverse override button is also the MODE button. See page 34.

NOTE: The transmission cannot be in reverse when using this feature.

Odometer Mode

The odometer records the miles traveled by the ATV.

Trip Meter Mode

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 deci-

Hour Meter Mode

This mode logs the total hours the engine has been in operation.

Tachometer Mode

The engine RPM is displayed digitally.

NOTE: Small fluctuations in the RPM from day to day may be normal because

Clock Mode

The clock displays time in a 12-hour format. To reset the clock, see page

50.

mal point, but the odometer displays without a decimal point.

of changes in humidity, temperature and elevation.

Page 50

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

The wrench icon will display when the gauge is in the diagnostic mode. To exit the diagnostic mode, turn the key switch off and on. Any movement of the tires will also cause the gauge to exit the diagnostic mode.

To enter the diagnostics mode:

1. Turn the key switch off and wait 10 seconds.

2. Lock the parking brake.

3. Place the transmission in neutral.

4. Hold the mode/reverse override button and turn the key switch on.

Release the switch as soon as the display is activated.

5. Use the mode button to toggle through the diagnostic screens.

Clock Screen

To reset the clock:

1. Enter the diagnostic mode.

2. Toggle to the clock screen.

3. Press and hold the mode button until the hour display flashes.

Release the button.

4. Press and release the mode button once to advance the setting by

one hour. Press and hold the mode button to advance the hours quickly.

5. When the desired hour is displayed, wait approximately four sec-

onds, until the minute display flashes.

6. Use the same procedure to reset the minutes.

7. When the display stops flashing, the mode has been set.

NOTE: Do not turn the key switch off until the display stops flashing or

the new setting will not be locked into the memory.

Page 51

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

Battery Voltage Screen

View this screen to check battery voltage level.

Tachometer Screen

View the tachometer to check engine speed.

4X4 Diagnostic Screen

The gauge indicates whether or not current is flowing through the allwheel-drive coil. This screen is for informational purposes only. Please see your dealer for all major repairs.

Gear Circuit Diagnostic Screen

This screen displays the resistance value (in ohms) being read at the gear switch input of the gauge. This screen is for informational purposes only. Please see your dealer for all major repairs.

Programmable service interval

When the hours of engine operation equal the programmed service interval setting, the wrench icon will flash for 5 seconds each time the engine is started. When this feature is enabled, it provides a convenient reminder to perform routine maintenance. See page 52.

NOTE: The service interval is programmed at 50 hours at the factory.

Page 52

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

Programmable service interval

To enable or disable the service interval:

1. Enter the diagnostic mode.

2. Toggle to the service interval screen.

3. Press and hold the mode button for about 7 seconds, until either ON

or OFF appears in the Rider Information Center, depending on your preference.

To reset the service interval:

1. Enter the diagnostic mode.

2. Toggle to the service interval screen.

3. Press and hold the mode button for 2-3 seconds, until the wrench

icon flashes. Release the button.

4. Press and release the mode button once to advance the setting by

one hour. Press and hold the mode button to advance the hours quickly.

NOTE: If you scroll past the intended number, press and hold the button until

5. When the desired setting is displayed, wait until the wrench icon

the hours cycle back to zero.

stops flashing. The new service interval is now programmed.

Miles/Kilometers toggle

The display in the tripmeter and odometer can be changed to display either standard or metric units of measurement.

1. Enter the diagnostic mode.

2. Toggle to the screen that displays either kilometers (KM) or miles

(MP).

3. Press and hold the mode button until the letters flash, then press and

release the button once. When the display stops flashing, the mode has been set.

Page 53

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Downloading Codes

The EFI diagnostic mode is for informational purposes only. Please see your Polaris dealer for all major repairs.

See page 55 for Blink Codes and Failure Descriptions. Use the following procedure to download blink codes (failure codes) from the EFI module.

1. Place the transmission in

PARK. Stop the engine. Turn the key switch to the ON position.

2. Turn the key switch off and

on three times in less than five seconds. The word “WAIt” will appear on the screen.

3. The Check Engine icon will blink once, pause, then blink twice

(blink code 12) to begin the diagnostic sequence. The EFI module is now searching for blink codes. If a code exists, the Check Engine icon will flash the code.

4. Count the number of times the Check Engine icon flashes. Example: For the two blink codes 42 and 36, the Check Engine icon will

flash 4 times, pause, then flash 2 times (code 42), then pause longer, blink 3 times, pause, and blink 6 times (code 36).

5. A code 61 will signal the end of the sequence. If no blink codes are

found, only codes 12 and 61 will appear during the sequence.

NOTE: The word “WAIt” will remain on the screen through this entire process.

Page 54

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Downloading Codes

Code Definitions

Open Load:

the chart (injector, fuel pump, etc.), or the item has failed.

Short-to-Ground:

control unit and the item listed in the chart.

Shorted Load:

shorted together, or the item has shorted internally.

Short-to-Battery:

the electronic control unit is shorted to a wire at battery voltage.

There is a break in the wires that lead to the item listed in

The wire is shorted to ground between the electronic

The wires leading to the item listed in the chart are

The wire leading from the item listed in the chart to

Page 55

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Downloading Codes

Blink Code

12 BEGIN SEQUENCE 22 Throttle Position Sensor Low 22 Throttle Position Sensor High 25 Gear Sensor Signal 31 System Voltage Low 31 System Voltage High 36 Ignition Coil A Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground 36 Ignition Coil A Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery 37 Ignition Coil B Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground 37 Ignition Coil B Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery 41 Air Temp Sensor Low Voltage 41 Air Temp Sensor High Voltage 42 Engine Coolant Temp Low Voltage 42 Engine Coolant Temp High Voltage 44 Crank Position Sensor Circuit Fault 45 Barometric Pressure/Manifold Air Pressure Sensor Low 46 Barometric Pressure/Manifold Air Pressure Sensor High 47 IAC Stepper Motor: Open Load 47 IAC Stepper Motor: Short-to-Ground 51 Injector Circuit Malfunction - Cyl 1: Open Load/Short-to-Ground 51 Injector Circuit Malfunction - Cyl 1: Shorted Load/Short-to-Battery 52 Injector Circuit Malfunction - Cyl 2: Open Load/Short-to-Ground 52 Injector Circuit Malfunction - Cyl 2: Shorted Load/Short-to-Battery 55 MIL Circuit: Open Load/Short-to-Ground 55 MIL Circuit: Shorted Load/Short-to-Battery 56 Fuel Pump: Open Load/Short-to-Ground 56 Fuel Pump: Shorted Load/Short-to-Battery 58 Fan Circuit: Open Load/Short-to-Ground 58 Fan Circuit: Shorted Load/Short-to-Battery 59 ADC: Open Load/Short-to-Ground 59 ADC: Shorted Load/Short-to-Battery 63 Starter Enable: Open Load/Short-to-Ground 63 Starter Enable: Shorted Load/Short-to-Battery 72 Gear Sensor Signal 73 4X4: Open Load/Short-to-Ground 73 4X4: Shorted Load/Short-to-Battery 74 Rear Differential Enable: Open Load/Short-to-Ground (if equipped) 74 Rear Differential Enable: Shorted Load/Short-to-Battery (if equipped) 61 END SEQUENCE

Failure Description

Page 56

OPERATION

Fuel Safety

WARNING

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

• Always refuel with the engine stopped, and outdoors or in a well ventilated area.

• Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

• Do not overfill the tank. Do not fill the tank neck.

• If gasoline spills on your skin or clothing, immediately wash it off with soap and water and change clothing.

• 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.

Page 57

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 41.

2. Check the engine oil level on the dipstick. See page 80. 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 58.

6. Pull only light loads.

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

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.

Page 58

OPERATION

Pre-Ride Checklist

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.

Item Remarks Page

Brake system/lever travel Ensure proper operation 37

Brake fluid Ensure proper level 38

Auxiliary brake Ensure proper operation 40

Front suspension Inspect, lubricate if necessary 79

Rear suspension Inspect, lubricate if necessary 79

Steering Ensure free operation -

Tires Inspect condition and pressure 97

Wheels/fasteners Inspect, ensure fastener tightness 97

Frame nuts, bolts, fasteners Inspect, ensure tightness -

Fuel and oil Ensure proper levels 41

Coolant level (if applicable) Ensure proper level 91

Coolant hoses (if applicable) Inspect for leaks -

Throttle Ensure proper operation 36

Indicator lights/switches Ensure operation 34

Engine stop switch Ensure proper operation 35

Air filter, pre-filter Inspect, clean 99

Air box sediment tube Drain deposits whenever visible -

Headlamp Check operation, apply Polaris dielec-

Brake light/taillight Check operation, apply Polaris dielec-

Riding gear Wear approved helmet, goggles, and

ADC Fluid Ensure proper level 89

tric grease when lamp is replaced

protective clothing

128

102

105

Page 59

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.

2. Place the transmission in PARK.

3. Lock the parking brake.

NOTE: The starter interlock will prevent the engine from starting if the trans-

4. Sit on the vehicle and move the engine stop switch to RUN.

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

5. Turn the ignition key past the ON position to engage the starter.

NOTE: The starter will automatically stop if engaged for longer than 5 sec-

6. If the engine does not start, return the key to the OFF position and

mission is in gear and the brake is not engaged.

Activate the starter for a maximum of five seconds, releasing the key when the engine starts.

onds. Move the key to the OFF position and wait 10 seconds before engaging the starter again.

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 contaminates such as water or excess fuel in the bottom of the crankcase. Water in the bottom of the crankcase can lead to engine damage and must be drained. Water accumulation increases as outside temperature decreases.

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

Page 60

OPERATION

1/3

2/3

Maximum

4" (10 cm)

Hauling Cargo

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 distri buted (1/3 on the fron t 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. Use low forward gear when hauling or towing heavy cargo to extend belt life.

Towing Loads

Always attach a towed load to the hitch point. If towing a load, reduce rear rack cargo weight by the amount of tongue weight. The combination of rear rack cargo weight and tongue weight must not exceed the rear rack capacity.

CAUTION

Using an improper hitch or exceeding the maximum tongue weight capacity can result in serious damage to the vehicle and will void your ATV warranty. Never install a hitch longer than 4" (10 cm). Never install automotive accessories on your Polaris ATV. Always install Polaris-approved (or equivalent) accessories designed for ATV use.

Page 61

OPERATION

Hauling Cargo

WARNING

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

REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO.

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

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.

SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create unstable operating conditions, which could result in loss of control of the vehicle.

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.

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.

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.

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

DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle should never exceed 10 mph (16 kph) while towing a load on a level 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.

Page 62

OPERATION

Driving Safely

Driving Procedures

1. Wear protective riding gear. See page 10.

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

3. Start the engine and allow it to warm up.

4. Shift the transmission into gear.

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

6. Release the parking brake.

7. Slowly depress the throttle with your right thumb and begin driving.

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

Page 63

OPERATION

Driving Safely

Turning the Vehicle

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 leaning technique should be used for turning in reverse.

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

faster speeds.

WARNING

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

Page 64

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 enter-

ing slippery areas.

2. Engage 4X4 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 4X4 is engaged while the wheels are spinning. Always allow the rear wheels to stop spinning before engaging 4X4, or engage 4X4 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.

Page 65

OPERATION

25° Maximum

Driving Safely

Driving Uphill

Whenever traveling uphill, follow these precautions:

1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 46.

2. Drive straight uphill.

3. Avoid steep hills (25° maximum).

4. Keep both feet on the footrests.

5. Shift your weight uphill.

6. Proceed at a steady rate of speed and throttle open ing.

7. 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.

Page 66

OPERATION

Driving Safely

Driving on a Sidehill (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 dangerous and should be avoided if at all possible. If you encounter a situation where sidehilling is necessary, follow these precautions:

1. Slow down.

2. Shift your weight uphill.

3. Keep your feet on the footrests.

4. Steer slightly into the hill to maintain vehicle direction.

NOTE: If the vehicle begins to tip, quickly turn the front wheel downhill, if pos-

sible, or dismount on the uphill side immediately!

Page 67

OPERATION

Driving Safely

Driving Downhill

WARNING

Excessive speed when traveling downhill can cause loss of control and serious injury or death. Slow down.

Applying the brakes too firmly may cause the rear wheels to lock, which could result in loss of control and serious injury or death. Apply the brakes gradually.

When driving downhill, follow these precautions:

1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 46.

2. Shift your weight uphill.

3. Drive straight downhill.

4. Slow down.

5. Squeeze the brake lever gradually.

NOTE: Before operating your ATV, learn how to use the auxiliary brake for

emergency situations (if single-lever brakes become inoperable).

Page 68

OPERATION

8 ft. (2.4 m)

Driving Safely

Turning Around on a Hill (K-Turn)

If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around.

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

2. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 46.

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

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

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

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

7. Lock the parking brake. Remount the vehicle from the uphill side, keeping body weight uphill.

8. Start the engine with the transmission still in forward.

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

Page 69

OPERATION

Maximum

Depth

Driving Safely

Driving Through Water

Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests. 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.

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 74. The following areas need special attention: engine oil, transmission oil, demand drive fluid, rear gearcase oil, and all grease fittings.

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 108. Have the vehicle serviced by your dealer at the first opportunity.

Page 70

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.

Page 71

OPERATION

Driving Safely

Driving in Reverse

Follow these precautions when operating in reverse:

1. Always check for obstacles or people behind the vehicle.

2. Always avoid backing

downhill.

3. Back slowly.

4. Apply the brakes

lightly for stopping.

5. Avoid turning at sharp

angles.

6. Never open the throttle suddenly.

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. Use the

override button with caution as rearward vehicle speed is greatly increased. Do not operate at wide open throttle.

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. Operate the throttle just enough to maintain a desired speed

Page 72

OPERATION

Driving Safely

Parking on an Incline

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

1. Stop the engine.

2. Place the transmission in PARK.

3. Lock the parking brake.

4. Always block the rear wheels on the downhill side.

Page 73

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.

The compliance label is located on the independent rear suspension (IRS) tube below the rear storage box.

Electromagnetic Interference

This spark ignition system complies with Canadian ICES-002. This vehicle complies with European directives 97/24/EC and 89/336/

EEC.

Page 74

MAINTENANCE

Periodic Maintenance Chart

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

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

Record maintenance and service in the Maintenance Log beginning on page 142.

NOTE: Service and adjustments are important for proper vehicle operation. If

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

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• 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.

you're not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

Page 75

MAINTENANCE

Periodic Maintenance Chart

Maintenance Chart Key

X Perform these operations more often for vehicles subjected to severe use.

E Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.)

Q Have an authorized Polaris dealer perform these services.

WARNING

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

Page 76

MAINTENANCE

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

Item Maintenance Interval

Q Steering - Pre-Ride - Make adjustments as need

X Front suspension - Pre-Ride - X Rear suspension - Pre-Ride -

Tires - Pre-Ride -

X Brake fluid level - Pre-Ride - X Brake lever travel - Pre-Ride -

Brake system - Pre-Ride -

Wheels/fasteners - Pre-Ride -

Frame fasteners - Pre-Ride -

X Engine oil level - Pre-Ride - XEAir filter, pre-filter - Daily - Inspect; clean often; replace

X Air box sediment

tube

Coolant (if applicable)

X ADC fluid

(ADC models)

Headlight/taillight/ work light

XEAir filter,

main element

Recoil housing (if applicable)

Brake pad wear 10 H Monthly 100 (160) Inspect periodically

Battery 20 H Monthly 200 (320) Check terminals; clean; test

X Demand drive fluid 25 H Monthly 250 (400) Inspect level; change yearly X Rear gearcase oil

(if equipped)

X Transmission oil 25 H Monthly 250 (400) Inspect level; change yearly XEEngine breather

filter (if equipped)

X Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service

Q Have an authorized Polaris dealer perform these services.

(whichever comes first)

Hours Calendar Miles

- Daily - Drain deposits when visible

- Daily - Check level daily, change

- Daily - Check level daily, add as

- Daily - Check operation; apply

- Weekly - Inspect; replace as needed

- Weekly - Drain water as needed,

25 H Monthly 250 (400) Inspect level; change yearly

25 H Monthly 250 (400) Inspect; clean if needed

(Km)

ed. See Pre-Ride Checklist on page 58.

as needed

coolant every 2 years

needed

dielectric grease if replacing lamps

check often if operating in wet conditions

Remarks

Page 77

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

X General

lubrication

Throttle Cable/

ETC Switch

E Throttle Body

Intake Duct

Drive belt 50 H 6 M 500 (800) Inspect; adjust; replace as

Cooling system (if applicable)

X Engine oil change 100 H 6 M 1000 (1600) Perform a break-in oil change

X Oil filter change 100 H 6 M 1000 (1600) Replace with oil change

Valve clearance 100 H 12 M 1000 (1600) Inspect; adjust

Fuel system 100 H 12 M 1000 (1600) Check for leaks at tank cap,

X Radiator

(if applicable)

X Cooling hoses

(if applicable)

X Engine mounts 100 H 12 M 1000 (1600) Inspect

Exhaust muffler/ pipe

Spark plug 100 H 12 M 1000 (1600) Inspect; replace as needed

X Wiring 100 H 12 M 1000 (1600) Inspect for wear, routing,

(whichever comes first)

Hours Calendar Miles

50 H 3 M 500 (800) Lubricate all fittings, pivots,

50 H 6 M 500 (800) Inspect; adjust; lubricate;

50 H 6 M 500 (800) Inspect duct for proper seal-

50 H 6 M 1000 (1600) Inspect coolant strength

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

(Km)

cables, etc.

replace if necessary

ing/air leaks

needed

seasonally; pressure test system yearly

at one month

lines, filter, pump; replace lines every two years

surfaces

security; apply dielectric grease to connectors subjected to water, mud, etc.

Remarks

Page 78

MAINTENANCE

Periodic Maintenance Chart

Item Maintenance Interval

Q Clutches (drive

and driven)

Q Front wheel

bearings

Q Brake fluid 200 H 24 M 2000 (3200) Change every two years

Q ADC fluid

(ADC models)

Fuel filter 200 H 24 M 2000 (3200) Check for leaks around lines.

Spark arrestor 300 H 36 M 3000 (4800) Clean out

Q Toe adjustment - Inspect periodically; adjust

Headlight aim - Adjust as needed

X Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service

Q Have an authorized Polaris dealer perform these services.

(whichever comes first)

Hours Calendar Miles

100 H 12 M 1000 (1600) Inspect; clean; replace worn

100 H 12 M 1000 (1600) Inspect; replace as needed

200 H 24 M 2000 (3200) Change every two years

(Km)

parts

Replace every 2 years, more often under extreme conditions.

when parts are replaced

Remarks

Page 79

MAINTENANCE

Front Prop Shaft Yoke

Lubrication Guide

Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 74. 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

Engine Oil PS-4 PLUS Performance

Brake Fluid DOT 4 Only --- See page 38.

Transmission Oil Polaris AGL Synthetic

Demand Drive Fluid (Front Gearcase)

ADC Fluid Polaris ADC Fluid --- See page 89.

Front Prop Shaft Yoke

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.

Item Lube Capacity at

Synthetic 2W-50

Gearcase Lube

Demand Drive LT Premium Fluid

Polaris Premium U-Joint Lube

Fluid Change

2 qt. (1.9 l) See page 80.

32 oz. (948 ml) See page 85.

9.3 oz. (275 ml) See page 87.

--- Grease fittings (3

Inspection Procedure

pumps maximum) every 500 miles, before long periods of storage, or after pressure washing or submerging.

Page 80

MAINTENANCE

Dipstick

Safe

Add Oil

{

Safe Range

Engine Oil

Oil Recommendations

Polaris recommends the use of Polaris PS-4 PLUS Performance Synthetic 2W -50 4-cycle oil or a similar oil for thi s engine. Oil may need to be changed more frequently if Polaris oil is not used. Always use 2W-50 oil. Follow the manufacturer's recommendations for ambient temperature operation. See page 133 for the part numbers of Polaris products.

CAUTION

Mixing brands or using a non-recommended oil may cause serious engine damage. Always use the recommended oil. Never substitute or mix oil brands.

Oil Level

Access the oil dipstick and fill tube from the left side of the ATV.

NOTE: A rising oil level between

1. Position the vehicle on a level

2. Start the engine. Allow it to idle

3. Remove the dipstick. Wipe it

4. Reinstall the dipstick com-

5. Remove the dipstick and check the oil level. Maintain the oil level

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.

surface.

for 20-30 seconds. Stop the engine.

dry with a clean cloth.

pletely.

in the safe range. Do not overfill.

Page 81

MAINTENANCE

Drain

Plug

Screen

Fitting

New Sealing Washer

Alignment Mark

Engine Oil

Oil and Filter Change

CAUTION

Hot oil can cause serious burns to skin. Do not allow hot oil to contact skin.

Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 74. Always change the oil filter whenever changing oil.

1. Position the vehicle on a level surface.

2. Start the engine. Allow it to idle for two to three minutes.

3. Stop the engine.

4. Clean the area around the drain plug.

5. Place a drain pan under the oil tank.

6. Remove the drain plug. Allow the oil to drain completely.

7. Install a new sealing washer on the drain plug.

NOTE: The sealing surfaces on drain

8. Reinstall the drain plug. To rque

9. Disconnect the lower oil deliv-

NOTE: The fitting threads must be sealed with LOCTITE PST 505 or PTFE

plug and crankcase should be clean and free of burrs, nicks or scratches.

to 14-17 ft. lbs. (19-23 Nm).

ery hose and remove the screen fitting from the oil tank. Clean the fitting.

seal tape.

Page 82

MAINTENANCE

Engine Oil

Oil and Filter Change

10. 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 on the tank.

NOTE: Do not over-tighten. Maximum torque for the screen fitting is 25 ft. lbs.

11. Reattach the oil line.

12. Place shop towels beneath the oil

13. Using a clean dry cloth, clean the

14. Lubricate the o-ring on the new

15. Install the new filter and rotate it clockwise by hand until the filter

16. Approximately one cup of engine oil will remain in the crankcase.

NOTE: The sealing surfaces on the drain plug and crankcase should be clean

(34 Nm).

filter. Using an oil filter wrench, turn the filter counterclockwise to remove it.

filter sealing surface on the crankcase.

filter with a film of fresh engine oil. Check to make sure the o-ring is in good condition.

gasket contacts the sealing surface, then turn it an additional 1/2 turn.

To drain, remove the drain plug on the lower right side of the crankcase.

and free of burrs, nicks or scratches.

Page 83

MAINTENANCE

Engine Oil

Oil and Filter Change

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

18. Remove the dipstick.

19. Add two quarts (1.9 l) of recommended oil. Reinstall the dipstick.

NOTE: If the sump is not drained, add about 1 3/4 quarts (1.6 l) initially.

20. Place the transmission in PARK.

21. Lock the parking brake.

22. Prime the oil pump using the procedure on page 84. Then stop

the engine and inspect for leaks.

23. Check the oil level. Add oil as needed to bring the level to the upper mark on the dipstick.

24. Dispose of used filter and oil properly.

Page 84

MAINTENANCE

Clamp

Pressure

Relief Slit

Tank

(5 cm)

Engine Oil

Oil and Filter 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 the vent line approximately 2" (5 cm) from the oil tank, between the end of the oil tank vent fitting and the vent line's pressure relief slit.

2. Start the engine. Allow it to idle

for 10-20 seconds.

3. Remove the vent line clamp. If the line is bled properly, you should

hear a rush of air, indicating that the line is properly primed and ready for operation.

NOTE: If you do not hear air, the line has not bled. Repeat the priming proce-

dure.

Page 85

MAINTENANCE

Drain Plug

Fill Plug

Transmission Oil

Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 74. Maintain the oil level at the bottom of the fill plug hole threads. We recommend the use of Polaris Premium AGL Synthetic Gearcase Lubricant. See page 133 for the part numbers of Polaris products.

The fill plug is located on the left side of the ATV, under the rear fender, behind the wheel.

The drain plug is located on the right side of the gearcase, on the right side of the ATV, behind the wheel well.

Oil Check

1. Position the vehicle on a level surface.

2. Remove the fill plug.

3. Check the oil level.

4. Reinstall the fill plug.Torque

to 22 ft. lbs. (30 Nm).

5. Reinstall the footwell.

Page 86

MAINTENANCE

Drain Plug

Transmission Oil

Oil Change

1. Remove the fill plug.

2. Place a drain pan under the gearcase.

3. Remove the drain plug. Allow the oil to drain completely.

4. Clean and reinstall the drain plug. Torque to 22 ft. lbs. (30 Nm).

5. Add 32 oz. (948 ml) of the recommended oil.

6. Reinstall the fill plug. Torque to 22 ft. lbs. (30 Nm).

7. Check for leaks.

8. Dispose of used oil properly.

Page 87

MAINTENANCE

Drain Plug

Fill Plug

Fill Level

Front Gearcase (Demand Drive) Fluid

Always check and change the demand drive fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 74. We recommend the use of Demand Drive LT Premium Fluid. Use of other fluids may result in improper operation of components. See page 133 for the part numbers of Polaris products.

Maintain the fluid level at the bottom of the fill hole threads. See below for capacity.

The fill plug is located on the right side of the demand drive unit. The drain plug is located on the bottom right side of the unit.

Demand Drive Capacities

Demand Drive with ADC 9.3 oz. (275 ml)

Page 88

MAINTENANCE

Front Gearcase (Demand Drive) Fluid

Fluid Check

1. Position the vehicle on a level surface. Remove the fill plug. Check

the fluid level.

2. Add the recommended demand drive fluid as needed to bring the level to the bottom of the fill hole threads.

3. Reinstall the fill plug. Torque to 8-10 ft. lbs. (11-14 Nm).

Fluid Change

1. Position the vehicle on a level surface. Remove the fill plug. Place a

drain pan under the demand drive unit.

2. Remove the drain plug. Allow the fluid to drain completely.

3. Clean and reinstall the drain plug. Torque to 11 ft. lbs. (15 Nm).

4. Add the recommended fluid. See page 87 for capacity. Maintain the fluid level at the bottom of the fill hole threads.

5. Reinstall the fill plug. Torque to 8-10 ft. lbs. (11-14 Nm).

6. Check for leaks. Dispose of used fluid properly.

Page 89

MAINTENANCE

ADC Fluid Reservoir

Active Descent Control (ADC) Fluid

Two fluid levels must be maintained on your vehicle, the demand drive fluid and the ADC fluid. See page 87 for demand drive fluid maintenance.

Check and change the ADC fluid level at the intervals outlined in the Periodic Maintenance Chart beginning on page 74. Maintain the fluid level between the minimum and maximum marks on the reservoir. We recommend the use of Polaris ADC Fluid. See page 133 for the part numbers of Polaris products.

Fluid Check

NOTE: Do not use brake fluid. Brake fluid will damage rubber components in

1. Open the front box cover.

2. Open the access door.

3. V iew the fluid level in the reservoir.

4. If the level is below the minimum

5. Reinstall the cap.

6. Secure the access door.

7. Secure the box cover.

the hydraulic system.

mark, remove the cap and add the recommended fluid.

Page 90

MAINTENANCE

Active Descent Control (ADC) Fluid

Fluid Change

1. Position the vehicle on a level surface. Before performing the fluid

change, allow the vehicle to sit for at least 30 minutes.

2. Thoroughly clean the areas around and on the ADC reservoir and bleeder valves (one on each side of the differential).

3. Remove the reservoir cap and diaphragm assembly. Use a shop towel or suction tool to remove debris from the fluid and reservoir.

NOTE: Debris in the reservoir may result in inadequate bleeding and reduced

4. Fill the reservoir to the maximum line with fresh ADC fluid.

5. Remove the protective caps from the bleeder valves.

6. Slowly loosen one of the valves (turn counter-clockwise) and allow

IMPORTANT: Close the bleeder valves before the reservoir fluid level drops below the minimum fill line. Adding fluid to an empty reservoir will result in trapped air. If the level drops below the minimum line, add fluid to the maximum line and repeat step 6 before proceeding.

7. Torque the valves to 80 in. lbs. (9 Nm). Reinstall the valve caps.

8. Add fresh ADC fluid to the reservoir until the level is between the

9. Reinstall the cap securely.

10. Clean up any drips or spills.

performance of the system.

fluid and trapped air to flow from the fitting. Close the valve when clean fluid begins to flow. Repeat this step for the remaining valve.

minimum and maximum marks. Make sure the reservoir is free of debris.

Page 91

MAINTENANCE

Cooling System

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

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

NOTE: Some coolant level drop on new vehicles is normal as the system is

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 133 for the part numbers of Polaris products.

NOTE: Always follow the manufacturer's mixing recommendations for the

Recovery Bottle Coolant

The recovery bottle is located on the left side of the vehicle.

1. Remove the left side panel.

2. Maintain the coolant level

3. Add coolant as needed.

purging itself of trapped air. Check the coolant level and maintain as recommended by adding coolant to the recovery bottle.

freeze protection required in your area.

See page 95.

between the minimum and maximum marks on the bottle (when the fluid is cool).

Page 92

MAINTENANCE

Radiator Cap

Cooling System

Radiator Coolant

To ensure that the coolant maintains its ability to protect the engine, Polaris recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water.

Replace the coolant any time the cooling system has been drained for maintenance or repair . If the recovery bottle has run dr y, check the level in the radiator. 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. Open the front box cover.

2. Open the access door.

3. Remove the pressure cap.

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

5. Reinstall the pressure cap.

6. Secure the access door.

7. Secure the box cover.

NOTE: Use of a non-standard

pressure cap will not allow the recovery system to function properly. Contact your dealer for the correct replacement part.

Page 93

MAINTENANCE

3/64" (1 mm)

Brakes

Hand Brake

The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. These brakes are selfadjusting.

Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced. To ensure proper diaphragm operation, always fill the reservoir as needed whenever the cover is loosened or removed. Do not overfill.

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.

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

1. Always keep brake fluid at an adequate level. See page 38.

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. Replace brake pads when they are worn to 3/64" (1 mm).

5. Check the security and surface condition

of the disc.

Auxiliary Foot Brake

The hydraulic auxiliary brake system requires no adjustment. Check the brake fluid level frequently for the auxiliary brake system. See page 40.

Page 94

MAINTENANCE

String

Stand

Toe Alignment

WARNING

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

Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8" to 1/4" (3-6 mm) toe out.

1. Position the vehicle on a level surface.

2. Place the handlebars in a

straight-ahead position.

3. Tie a length of string

between two stands as shown in the illustration. Position the stands so that the string is flush with the side of the rear tire.

NOTE: If available, you may

4. Measure the distance

5. Repeat the measurement procedure on the other side of the vehicle.

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

use a long straightedge instead of string.

from the string to the rim at the front (1) and rear (2) of the front rim. The rear measurement should be 1/16"-1/8" (2-3 mm) more than the front measurement on each side of the vehicle to obtain the recommended 1/8" to 1/4" (3-6 mm) toe out alignment.

Page 95

MAINTENANCE

Step 1 Step 2 Step 3

Screws

Rivets

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. Pull the panel downward and rearward to remove it.

3. When reinstalling side panels, align the fasteners and press firmly to secure them.

Footwell Removal

1. Remove the four screws on

the bottom of the footwell.

2. Use a flat screwdriver or sidecutters to remove the plastic rivets securing the footwell to the fenders.

3. Remove the footwell.

Page 96

MAINTENANCE

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.

Tires

Refer to the specifications section beginning on page 134 for recommended tire type, size and pressure.

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 mm) or less.

Page 97

MAINTENANCE

1/8" (3 mm)

Tires

Tire Tread Depth

Always replace tires when tread depth is worn to 1/8" (3 mm) or less.

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.

Wheel Removal

1. Stop the engine.

2. Place the transmission in PARK.

3. Lock the parking brake.

4. Loosen the wheel nuts slightly.

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

6. Remove the wheel nuts.

7. Remove the wheel.

Page 98

MAINTENANCE

Cast Aluminum Steel

90 ft. lbs. (122 Nm)

27 ft. lbs.

(37 Nm)

Tires

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.

2. Lock the parking brake.

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

4. Install the wheel nuts and finger-tighten them.

5. Lower the vehicle to the ground.

6. Torque the wheel nuts to specification.

Wheel Nut Torque Specifications

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

Nut Type Nut Torque

Lug Nut 90 ft. lbs. (122 Nm)

2-Piece Flange Nut 27 ft. lbs. (37 Nm)

Page 99

MAINTENANCE

Main Filter

Pre-Filter

Breather

Filter

Air Filter

1. Remove the seat.

2. Release the air box cover clips, and remove the air box cover.

3. Loosen the clamp and remove the filter.

4. Remove the fabric type prefilter from the main filter. Wash the pre-filter in soapy water, then rinse and let dry.

5. Reinstall the pre-filter over the main filter.

NOTE: Install a new main filter if

6. Reinstall the filter into the air box and tighten the clamp. Do not

7. Reinstall the air box cover and the seat.

needed.

over-tighten the clamp, as filter damage could occur .

Page 100

MAINTENANCE

Breather Filter/Hose

The breather filter is on the hose that runs between the engine and air box. See illustration above.

1. Remove the left side panel. See page 95.

2. Remove the hose clamps from the filter and pull the filter out of the hoses.

3. Inspect the filter for debris. Blow gently through the filter in the direction of the arrow to check for clogging. Replace a damaged or clogged filter.

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

5. Reinstall the filter and hose 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 it for service.

100