Polaris Sportsman 9921825 User Manual

2

WARNING

The engine exhaust from this product contains

chemicals known to the State of California to cause

cancer, birth defects or other reproductive harm.

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

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.com.
Have your accessories and clothing delivered right to your door!

1

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

Copyright 2008 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.
2009 Sportsman 500 Owner’s Manual
P/N 9921825

2

TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Features and Controls . . . . . . . . . . . . . . . . . . . 24

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Emission Control Systems . . . . . . . . . . . . . . . 61

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 115

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 119

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 120

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 128

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

3

INTRODUCTION

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 indicates a potential personal injury hazard.

WARNING

A WARNING indicates a hazardous situation which, if not avoided, may result in
death or serious injury.

CAUTION

A CAUTION indicates a hazardous situation which, if not avoided, may result in
minor or moderate injury.

NOTICE

A NOTICE indicates a situation that may result in property damage.

The Prohibition Safety Sign indicates an action NOT to take in order
to avoid a hazard.

The Mandatory Action Sign indicates an action that NEEDS to be
taken to avoid a hazard.

4

INTRODUCTION

WARNING

Failure to heed the warnings and safety precautions 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 this owner’s manual. Understand all safety warnings, precautions and
operating procedures before operating a Polaris ATV. Keep this manual with
the ATV.

• 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
[phone] or visit www.atvsafety .org for information on enrollment in the
ATV RiderCoursesm.

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

• Never permit a guest to operate the ATV unless the guest has read this
manual and all product labels and has completed a certified safety training
course.

sm

. Contact ATV Enrollment Express at

5

INTRODUCTION

####

VIN

Engine Serial Number

Key Number

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: ___________________________________________________________

6

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

RiderCourse

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 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.

We strongly adv is e 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.

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 1-800­342-3764.

sm

available to you and your eligible family members. This

sm

. You were also provided with

sm

by calling A TV Enrollment Express at [phone] or

7

SAFETY

Helmet

Eye Protection

Gloves

Boots

Long Pants

Long

Sleeves

E

4

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.

8

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.

Equipment Modifications

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.

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

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

9

SAFETY

WARNING

Safety Warnings

Failure to operate the ATV properly can result in a collision, loss of control,
accident or overturn, which may result in serious injury or death. Heed all safety
warnings outlined in this section of the owner’s manual. See the OPERATION
section of the owner’s manual for proper operating procedures.

Operating Without Instruction

Operating this ATV without proper instruction
increases the risk of an accident. The operator
must understand how to operate the ATV properly
in different situations and on different types of
terrain.

Beginning and inexperienced operators should
complete the recommended safety training before
operating this vehicle. See page 7.

Never permit a guest to operate the ATV unless the
guest has read this manual and all product labels
and has completed a certified safety training
course.

Age Restrictions

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

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

10

SAFETY

Safety Warnings

Handling Gasoline

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.

• Turn the fuel valve off whenever the vehicle is stored or parked.

Exposure to Exhaust

Engine exhaust fumes are poisonous and can cause loss of consciousness or
death in a short time. Never start the engine or let it run in an enclosed area.

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.

Failure to Inspect Before Operating

Failure to inspect and verify that the ATV is in safe
operating condition before operating increases the
risk of an accident.

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

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

11

SAFETY

Safety Warnings

Protective Apparel

Riding in this vehicle without wearing an
approved helmet and protective eyewear
increases the risk of a serious injuries in the
event of an accident.

Operator and passenger must always wear an
approved helmet that fits properly and eye
protection (goggles or face shield).

Using Alcohol or Drugs

Operating the ATV after consuming
alcohol or drugs could adversely affect
operator judgment, reaction time,
balance and perception.

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

Carrying a Passenger

Carrying a passenger greatly reduces the
operator's ability to balance and control the
ATV, which may result in an accident or
overturn.

Never carry a passenger on this ATV.

12

Safety Warnings

Operating on Pavement

Operating an ATV on paved surfaces
(including sidewalks, paths, parking lots and
driveways) may adversely affect the
handling of the ATV and could result in loss
of control and accident or overturn.

Avoid operating the A T V on pavement. AT V
tires are designed for off-road use. If it's
unavoidable, travel slowly and avoid sudden
turns or stops.

Operating on Public Roads

Operating this ATV on public streets, roads
or highways could result in a collision with
another vehicle.

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

Operating at Excessive
Speeds

Operating the ATV at excessive speeds
increases the operator's risk of losing
control.

Always operate at a speed that's
appropriate for the terrain, the visibility and
operating conditions, and your experience.

SAFETY

13

SAFETY

Safety Warnings

Physical Control of the ATV

Removing a hand from the handlebars or
feet from the footrests during operation can
reduce your ability to control the vehicle or
cause loss of balance and ejection from the
AT V. If the operator's foot is not firmly
planted on the footrest, it could also contact
the rear wheels.

Never remove your hands from the
handlebars while operating, and always
keep both feet on the footrests.

Turning Improperly

Turning improperly could cause loss of
traction, loss of control, accident or overturn.

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

Never turn abruptly or at sharp angles. Never
turn at high speeds. Practice turning at slow
speeds before attempting to turn at faster
speeds.

Jumps and Stunts

Attempting wheelies, jumps and other
stunts increases the risk of an accident or
overturn.

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

Improper Hill Climbing

Improper hill climbing could cause loss of
control or overturn. Always follow proper
procedures for climbing hills as described in
the owner's manual. See page 51.

14

SAFETY

Safety Warnings

Descending Hills Improperly

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

• Always follow proper procedures for travel­ing down hills as described in the own e r 's
manual. NOTE: A special technique is
required when braking while traveling down­hill. See page 53.

• Always descend a hill with the transmission
in forward gear. Do not descend a hill with
the transmission in neutral.

• 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.

Crossing Hillsides

Driving on a sidehill is not recommended.
Improper procedure could cause loss of control
or overturn. Avoid crossing the side of any hill
unless absolutely necessary.

If crossing a hillside is unavoidable, always follow
proper procedures as described in the owner's
manual. See page 52.

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 54.

15

SAFETY

Safety Warnings

Stalling While Climbing a Hill

Stalling, rolling backwards or improperly
dismounting while climbing a hill could cause an
overturn.

• Always maintain a steady speed when climbing
a hill.

If all forward speed is lost:

• Keep body weight uphill.

• Apply the brakes.

• Lock the parking brake when fully stopped.

• 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 54.

If the ATV begins rolling downhill:

• Keep body 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 54.

Operating on Steep Hills

Operating on excessively steep hills could cause
an overturn.

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

16

Safety Warnings

Operating on Slippery Terrain

Failure to use extra caution when operating on
excessively rough, slippery or loose terrain could
cause loss of traction, loss of control, accident or
overturn.

Do not operate on excessively rough, slippery or
loose terrain. Always use extra caution on rough,
slippery or loose terrain.

Operating in Unfamiliar Terrain

Failure to use extra caution when operating on
unfamiliar terrain could result in an accident or
overturn.

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

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

SAFETY

17

SAFETY

Safety Warnings

Operating Improperly in Reverse

Improperly operating in reverse could result in a collision with an obstacle or
person. Always follow proper operating procedures as outlined in this manual.
See page 57.

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

Improper Tire Maintenance

Operating this ATV with improper tires
or with improper or uneven tire
pressure could cause loss of control or
accident.

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

Always maintain proper tire pressure as
described in the owner's manual and
on safety labels.

Operating Over Obstacles

Improperly operating over obstacles could cause loss of control or overturn.
Before operating in a new area, check for obstacles. Avoid operating over large

obstacles such as rocks and fallen trees. If unavoidable, use extreme caution
and always follow proper operating procedures as outlined in this manual. See
page 57.

Skidding or Sliding

Skidding or sliding can cause loss of control or overturn (if tires regain traction
unexpectedly).

On slippery surfaces such as ice or loose gravel, travel slowly and use extra
caution to reduce the chance of skidding or sliding. Do not operate on
excessively slippery surfaces.

18

SAFETY

Safety Warnings

Operating Through Deep Water

Operating the ATV through deep or fast­flowing water could cause the tires to float,
causing loss of control or overturn.

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

55):

• Travel slowly.

• Balance your weight carefully.

• Avoid sudden movements.

• 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. After leaving water, test the

brakes. Apply them lightly several times while driving slowly. The friction will
help dry out the pads.

Improper Cargo Loading

Overloading the ATV or carrying/towing cargo improperly may cause changes in
handling, which could cause loss of control or an accident.

• 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 dis-

tance for braking.

• Always follow the instructions in the owner's manual for carrying cargo or pull-

ing a trailer.

19

SAFETY

Safety Warnings

Operating on Frozen Bodies of Water

Operating on frozen bodies of water may result in serious injury or death if the
ATV and/or the operator fall through the ice.

Never operate the ATV on a frozen body of water.

Poor Visibility

Operating the ATV in darkness or inclement weather could result in a collision or
accident, especially if operating on a road or street. This AT V is not equipped
with highway-approved lights. Operate this vehicle off-road only. Use caution
and drive at reduced speeds in conditions of reduced visibility such as fog, rain
and darkness. Clean headlights frequently and replace burned out headlamps
promptly.

Operating a Damaged ATV

Operating a damaged ATV can result in an accident. 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.

Physical Skills

Safe operation of this rider-active vehicle requires good judgement and physical
skills. Persons with cognitive or physical disabilities who opera te this vehicle
have an increased risk of overturn and loss of control.

Hot Exhaust Systems

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

Unauthorized Use of the ATV

Leaving the keys in the ignition can lead to unauthorized use of the vehicle,
which could result in an accident or overturn. Always remove the ignition key
when the vehicle is not in use.

20

SAFETY

Safety Decals and Locations

Warning labels hav e been placed on the vehicle for your protection.
Read and follow the instructions on each label carefully. If any of the
labels shown in this manual differ from the labels on your vehicle,
always read and follow the instructions of the labels on the vehicle.

If an informational or graphic label becomes illegible or comes off, con­tact your Polaris dealer to purchase a replacement. Replacement safety
labels are provided by Polaris at no charge. The part number is printed
on the label.

General Warning/Discretionary 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 OPERATOR’S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.

WARNING

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

vent overturn on hilly terrain, use throttle and brakes gradually, and shift
weight uphill.

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

becomes difficult. To prevent loss of control, avoid sudden braking or sharp
turns.

7175553

21

SAFETY

+

+

Tire Pressure/Load

Warning

General Warning

Discretionary Warning

+

“No Passenger”

Warning

+

Age 16 Warning

Safety Decals and Locations

Tire Pressure/Load Warning

WARNING
Improper tire pressure or overloading can cause loss of control.
Loss of control can result in severe injury or death.

• Cold tire pressure:

Front: 5.0 psi (34.5 kPa)
Rear: 5.0 psi (34.5 kPa)

• Maximum weight capacity: 485 lbs. (220 kg)

7175642

“No Passenger” Warning

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

DEAT H.

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.

22

7175378

7175374

SAFETY

+

Clutch Cover

Warning

+

+

Rack

Warning

Rack

Warning

Safety Decals and Locations

Clutch Cover Warning

WARNING

• 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.

NO STEP

7172563

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)

7172572

Reverse Override Warning/4X4 Caution

WARNING
Pushing reverse override button may cause sudden increases in power and

traction if too much throttle is applied. Loss of control or forward flipover may
result, especially in AWD. See Owner's Manual.

CAUTION
Do not push switch to engage AWD if the rear wheels are spinning. This may

cause severe drive shaft and clutch damage. See your Owner's Manual.

7175512

23

FEATURES AND CONTROLS

Mode/Reverse

Override

Switch

Worklight

Switch

(if equipped)

Main Key Switch

Engine

Stop Switch

Headlight

Switch

Choke

AWD Switch

Switches

Mode/Reverse Override Switch

This vehicle is equipped with a reverse speed limiter system. To gain
additional wheel speed while backing, release the throttle and depress
the override button.

WARNING! Pressing the override button while the throttle is open can cause
loss of control, which may result in serious injury or death. Always release the
throttle before pressing the override button.

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 35.

AWD Switch

Use the AWD switch to engage 4X4 or 2X4. See page 34.

24

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.

Both the main switch and the engine stop switch will shut off all electri­cal power to the vehicle, including lights.

Main Key Switch

Use the main key switch to start the engine. See page 46 for starting pro­cedures.

Worklight Switch

Use the worklight switch (if equipped) to turn the worklight on or off.
The worklight is located at the rear of the vehicle. Turn the light on
while loading and unloading cargo in low light situations. Turn the
worklight 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. The key must be in the ON position
and the engine stop switch must be in the RUN position to operate the
headlights.

25

FEATURES AND CONTROLS

WARNING

Throttle Lever

Operating an ATV with sticking or improperly operating throttle controls could
cause an accident. Never start or operate an ATV that has a sticking or
improperly operating throttle. Always contact your dealer for service before
operating the vehicle.

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.

Modifications to the electronic throttle control could result in failure to perform as
designed, which could result in an accident. Do not attempt to modify the throttle
control system or replace it with any after market throttle mechanisms. Always
ensure that the throttle cable is installed and properly routed to the throttle
control.

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.

26

FEATURES AND CONTROLS

WARNING

Brake Lever

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. Always contact your dealer for service before operating the vehicle.

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.

27

FEATURES AND CONTROLS

WARNING

Master Cylinder

Indicator

Window

Master Cylinder/Brake Fluid

An over-full master cylinder may cause brake drag or brake lock-up, which could
result in an accident. 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 brake failure, which could result in an accident. After
opening a bottle of brake fluid, always discard any unused portion.

Check the brake fluid in the master
cylinder before each ride.

1. Position the ATV on a level

surface.

2. Position the handlebars so the

master cylinder is level.

3. View the brake fluid level

through the indicator window
on the top of the master cylin­der. The eye will appear dark
when the fluid level is full.
When fluid is low, the eye will be clear.

4. If the fluid level is low add DOT 4 brake fluid only. Do not overfill.

28

FEATURES AND CONTROLS

Parking Brake

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.

WARNING! Operating the ATV while the parking brake is engaged could result
in an accident or fire. Always check to be sure the parking brake is disengaged
before operating.

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 ATV 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.

29

FEATURES AND CONTROLS

WARNING

Auxiliary Foot Brake

Auxiliary Foot Brake

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, which may result in serious injury or death.

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. Since this is a rear brake only , it will not be as ef fective as the all­wheel single lever system.

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

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

Brake Fluid Level

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

30

FEATURES AND CONTROLS

OFF

ON

Fuel

Tank

Cap

Choke

The choke assists in starting a cold engine. Refer to the engine starting
procedure on page 46 for correct choke and throttle settings during start­ing.

Fuel Valve

The fuel valve is located under the
front storage box cover.

OFF: For vehicle storage and when
transporting.

ON: For normal operation.

Fuel Tank Cap

This vehicle is equipped with a
digital fuel gauge that will
indicate a low fuel condition.
Refuel when the gauge indi­cates a low fuel condition.

Always refuel with the engine
stopped, and outdoors or in a
well ventilated area. Refuel on
a level surface.

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 100
hours of operation, or annually. Do not attempt to clean the fuel filter.

31

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

To shift gears, brake to a
complete stop. When the
engine is idling, move the
lever to the desired gear.

NOTICE: Shifting gears with

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

Belt Life

T o extend belt life, use low forward gear in heavy pulling situations and
when operating at less than seven miles per hour for extended periods of
time.

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

32

FEATURES AND CONTROLS

AWD

Switch

All Wheel Drive (AWD) System

The All Wheel Drive system is
controlled by the AWD switch.
When the switch is on 2X4, the
ATV is in two-wheel drive at all
times. When the switch is on
AWD, the ATV is in all wheel
drive and the A WD indicator light
in the instrument cluster will be
on.

When in AWD, 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.

Tip: The override switch allows activation of AWD in reverse if the AWD switch

is on. See page 24.

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

Engaging A WD

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

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

33

FEATURES AND CONTROLS

Active Descent Control (ADC) System

The ADC system (if equipped) allows engi ne braking to all fou r wheels
when the vehicle descends a hill or incline. If your ATV is equipped
with Active Descent Control, always engage AWD 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 AWD switch must be in the AWD 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 AWD switch is moved to the 2X4 position

• Vehicle speed exceeds 15 mph (24 km/h)

• The throttle is open (throttle is applied)

• The transmission is shifted to neutral or park

34

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. In addition to showing vehicle speed,
the speedometer needle flashes when a warning condition exists.

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 (11-14 km/h). Refer to page 24
for additional information.

NOTICE: 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.

35

FEATURES AND CONTROLS

1

2

345

6

7

9

8

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. If the instrument cluster
fails to illuminate, a battery over-voltage may have occurred and the
instrument cluster may have shut off to protect the electronic speedome­ter. If this occurs, take the ATV to your Polaris dealer for proper diagno­sis.

1. Gear Indicator - This

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

2. AWD Indicator - This

indicator illuminates
when the AWD switch
is in the AWD position.

3. Engine Hour Display Indicator

4. Service Interval/Diagnostic Mode Indicator

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

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.

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

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

in the fuel tank. When the last segment clears, a low fuel warning is
activated. All segments will flash, FUEL will display in the LCD,
and the speedometer needle will blink. Refuel immediately.

8. Check Engine Warning Indicator - The word HOT displays if the

engine overheats. Do not operate the ATV if this warning appears.
Serious engine damage could result.

9. Mode Indicator

36

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 24. 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. In the Rider Information Center, the trip meter display contains a
decimal point, but the odometer displays without a decimal point.

Hour Meter Mode

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

Tachometer Mode

The engine RPM is displayed digitally. Small fluctuations in the RPM
from day to day may be normal because of changes in humidity, temper­ature and elevation.

Clock Mode

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

38.

37

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.

8. Do not turn the key switch off until the display stops flashing or the

new setting will not be locked into the memory.

38

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.

AWD Diagnostic Screen

The gauge indicates whether or not current is flowing through the AWD
coil (only on models with switchable AWD). 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 40.

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

39

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.

5. If you scroll past the intended number, press and hold the button

until the hours cycle back to zero.

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

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.

40

OPERATION

WARNING

Failure to operate the ATV properly can result in a collision, loss of control,
accident or overturn, which may result in serious injury or death. Read and
understand all safety warnings outlined in the safety section of this owner’s
manual.

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.

NOTICE: 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.

41

OPERATION

Break-In Period

Engine and Drivetrain Break-in

1. Fill the fuel tank with gasoline. See page 31. Always exercise

extreme caution whenever handling gasoline.

2. Check the oil level on the dipstick. See page 69. Add oil if neces-

sary to maintain the level between the safe and add marks.

3. Drive slowly at first. Select an open area that allows room to famil-

iarize 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 45.

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.

42

OPERATION

Safe Operation Practices

1. Complete the recommended safety training before operating this

vehicle. See page 7.

2. Do not allow anyone under 16 years of age to operate this vehicle.

Do not allow anyone with cognitive or physical disabilities to oper­ate this vehicle.

3. Never carry a passenger on this ATV.

4. Engine exhaust fumes are poisonous. Never start the engine or let it

run in an enclosed area.

5. Before operating, learn how to use the auxiliary brake for emer-

gency situations (if service brakes become inoperable).

6. Operate this vehicle off-road only. Never operate the vehicle on

pavement or on any public street, road or highway, including dirt
and gravel roads.

7. Use caution and drive at reduced speeds in conditions of reduced

visibility such as fog, rain and darkness. Clean headlights fre­quently and replace burned out headlamps promptly.

8. Drive in a manner appropriate for your skills and operating condi-

tions. Never operate at excessive speeds. Never attempt wheelies,
jumps, or other stunts. Never remove your hands from the handle­bars while operating, and always keep both feet on the footrests.

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

10. Always use the size and type of tires specified for your vehicle.

Always maintain proper tire pressure.

11. Never operate a damaged ATV. After any overturn or accident,

have a qualified service dealer inspect the entire machine for possi­ble damage.

12. Never operate the ATV on a frozen body of water.

13. Do not touch hot exhaust system components. Always keep com-

bustible materials away from the exhaust system.

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

prevent unauthorized use.

43

OPERATION

Know Your Riding Area/Tread Lightly

Familiarize yourself with all laws and regulations concerning the opera­tion of this off-road vehicle in your area. Respect the environment in
which you ride. Find out where the designated riding areas are by con­tacting your Polaris dealer, a local riding club or local officials.

Help keep our trails open for recreational vehicle use. As an off-road
enthusiast, you represent the sport and can set a good example (or a poor
example) for others to follow . T read lightly. Operate with respect for the
terrain, avoid littering, and always stay on the designated trails.

Trail Etiquette

Always practice good etiquette when riding. Allow a safe distance
between your vehicle and other vehicles operating in the same area.
Communicate to oncoming operators by signaling the number of vehi­cles in your group. When stopping, move your vehicle to the edge of the
trail as far as possible to allow others to pass safely.

44

OPERATION

Pre-Ride Checklist

Failure to inspect and verify that the ATV is in safe operating condition
before operating increases the risk of an accident. Always inspect the
ATV before each use to make sure it's in safe operating condition.

Item Remarks Page

Brake system/lever travel Ensure proper operation 27

Brake fluid Ensure proper level 28

Auxiliary brake Ensure proper operation 30

Front suspension Inspect, lubricate if necessary 67

Rear suspension Inspect, lubricate if necessary 67

Steering Ensure free operation -

Tires Inspect condition and pressure 83

Wheels/fasteners Inspect, ensure fastener tightness 83

Frame nuts, bolts, fasteners Inspect, ensure tightness -

Fuel and oil Ensure proper levels 31

Coolant level (if applicable) Ensure proper level 78

Coolant hoses (if applicable) Inspect for leaks -

Throttle Ensure proper operation 26

Indicator lights/switches Ensure operation 24

Engine stop switch Ensure proper operation 25

Air filter, pre-filter Inspect, clean 85

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

tric grease when lamp is replaced

tric grease when lamp is replaced

protective clothing

80

84

69

79

114

25
88

91

8

45

OPERATION

Tension

Adjusting Nut

Starting the Engine

1. Position the vehicle on a level surface outdoors or in a well-venti-

lated area.

2. Place the transmission in PARK.

3. Lock the parking brake.

Tip: The starter interlock will prevent the engine from starting if the transmission

is in gear and the brake is not engaged.

4. Turn the fuel valve on.

5. Sit on the vehicle.

6. Do not use the choke if starting a warm engine. Excessive use of the

choke can cause the spark plug to become wet fouled.

7. If the engine is cold, pull the

choke knob out until it stops.

Tip: The variable choke is fully on

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

8. If the knob doesn't stay where

positioned, increase the ten­sion by rotating the tension
adjusting nut clockwise.

9. Move the engine stop switch to RUN.

10. Do not press the throttle while starting the engine.

46

OPERATION

Starting the Engine

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

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

NOTICE: Operating the vehicle immediately after starting could cause engine

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

Tip: If a warm engine has cooled to a point where it does not readily start, inter-

13. If the engine slows or stops, position the choke knob half way in to

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. W ater 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.

damage. Allow the engine to warm up for several minutes before
operating the vehicle.

wait five seconds before attempting to start again. Activate the
starter for another five seconds if necessary. Repeat this procedure
until the engine starts.

mittent use of the choke button (pulled half way out) may be necessary. If
the engine is over-choked when warm, depress the throttle lever fully while
cranking to aid in starting. Release the throttle lever immediately after the
engine starts. If the engine does not start and all conditions are favorable,
change the spark plug and try again.

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

47

OPERATION

Driving Procedures

1. Wear a helmet and eye protection. See page 8.

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.

48

OPERATION

Turning the Vehicl e

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.

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

WARNING! Turning improperly can result in vehicle overturn. Never turn
abruptly or at sharp angles. Never turn at high speeds.

49

OPERATION

Sideways

skid

Turn in

direction of

skid

Driving on Slippery Surfaces

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

1. Do not operate on excessively rough, slippery or loose terrain.

2. Slow down when entering slippery areas.

3. Engage AWD before wheels begin to lose traction.

NOTICE: Severe damage to drive train may occur if the AWD is engaged while

the wheels are spinning. Allow the rear wheels to stop spinning
before engaging AWD, or engage AWD before wheels begin to lose
traction.

4. Maintain a high level of alertness, reading the trail and avoiding

quick, sharp turns, which can cause skids.

5. Never apply the brakes during a skid. Correct a skid by turning the

handlebars in the direction of the skid and shifting your body
weight forward.

50

OPERATION

25° Maximum

Driving Uphill

Braking and handling are greatly affected when operating in hilly ter­rain. Improper procedure could cause loss of control or overturn. When­ever traveling uphill, follow these precautions:

1. If your ATV is equipped with Active Descent Control, always

engage AWD before ascending a hill. See page 34.

2. Drive straight uphill.

3. Avoid steep hills (25° maximum).

4. Always check the terrain carefully before ascending any hill.

5. Never climb hills with excessively slippery or loose surfaces.

6. Keep both feet on the footrests.

7. Shift your weight uphill.

8. Proceed at a steady rate of speed and throttle opening. Opening the

throttle suddenly could cause the ATV to flip over backwards.

9. Remain alert and be prepared to take emergency action. This may

include quick dismounting of the vehicle.

51

OPERATION

Driving on a Sidehill (Sidehilling)

Driving on a sidehill is not recommended. Improper procedure could
cause loss of control or overturn. Avoid crossing the side of any hill
unless absolutely necessary.

If crossing a sidehill is unavoidable, follow these precautions:

1. Slow down.

2. Avoid crossing the side of a steep hill.

3. Shift body weight uphill.

4. Keep your feet on the footrests.

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

6. If the vehicle begins to tip, quickly turn the front wheel downhill, if

possible, or dismount on the uphill side immediately!

52

OPERATION

Driving Downhill

When driving downhill, follow these precautions:

1. If your ATV is equipped with Active Descent Control, always

engage AWD before descending a hill. See page 34.

2. Avoid steep hills (25° maximum).

3. Shift body weight uphill.

4. Drive straight downhill.

5. Slow down. Excessive speed when traveling downhill can cause

loss of control.

6. Squeeze the brake lever gradually. Applying the brakes too firmly

may cause the rear wheels to lock, which could result in loss of con­trol.

53

OPERATION

8 ft. (2.4 m)

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. If your ATV is equipped with Active Descent Control, en gage

AWD. See page 3 4.

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 vehi-

cle 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.

54

OPERATION

Maximum

Depth

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 entering
water.

2. Choose a crossing where

both banks have gradual
inclines.

3. Avoid operating through

deep or fast-flowing water.

NOTICE: Major engine damage can result if the vehicle is not thoroughly

4. After leaving water, test the brakes. Apply them lightly several

If it’s unavoidable to enter water deeper than the footrest level:

• Proceed slowly. Avoid rocks and obstacles.

• Balance your weight carefully. Avoid sudden movements.

• Maintain a steady rate of speed. Do not make sudden turns or stops.

Do not make sudden throttle changes.

inspected after operation in water. Perform the services outlined in
the maintenance chart. See page 62. The following areas need
special attention: engine oil, transmission oil, demand drive fluid, rear
gearcase oil, and all grease fittings

If the vehicle tips or overturns in water, or if the engine stops during
or after operating in water, restarting can result in serious engine
damage. Transport the vehicle to your dealer for service before
restarting the engine. If this is not possible, follow the vehicle
immersion inspection and drying procedures outlined on page 94,
then see your dealer for service at the first opportunity.

.

times while driving slowly. The friction will help dry out the pads.

55

OPERATION

Driving Over Obstacles

Follow these precautions when operating over obstacles:

1. Always check for obstacles before operating in a new area.

2. Look ahead and learn to read the terrain. Be constantly alert for haz-

ards such as logs, rocks and low hanging branches.

3. Travel slowly and use extra caution when operating on unfamiliar

terrain. Not all obstacles are immediately visible.

4. Never attempt to operate over large obstacles, such as rocks or

fallen trees.

56

OPERATION

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.

7. Do not use the override button unless additional wheel speed is

required for vehicle movement. Use the override with caution as
rearward vehicle speed is greatly increased. Do not operate at wide
open throttle. Operate the throttle just enough to maintain a desired
speed.

NOTICE: Excessive throttle operation while in the speed limit mode may cause

fuel to build in the exhaust, resulting in engine popping and/or engine
damage.

57

OPERATION

WARNING

Hauling Cargo

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.

NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle. When
determining the weight you are adding to the vehicle, include the weight of the
operator, accessories, loads in the rack or box and the load on the trailer
tongue. The combined weight of these items must not exceed the maximum
weight capacity.

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 RECOMME NDED 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.

58

OPERATION

1/3

2/3

Maximum

4" (10 cm)

Hauling Cargo

Never exceed the weight capac­ities specified for your ATV on
warning labels and in the speci­fications section of this manual.

Cargo weight should be evenly
distributed (1/3 on the front
rack and 2/3 on the rear rack)
and mounted as low as possible.
When operating over rough or
hilly terrain, reduce speed and
cargo weight to maintain stable
driving conditions. Do not
obstruct the headlight beam
with cargo. 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. Remove the hitch from
the ATV when not towing a trailer. 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.

• The total load (operator, accessories, car go an d weight on hitch) must

not exceed the maximum weight capacity of the vehicle.

NOTICE: 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 insta ll a hitch longer
than 4" (10 cm). Never install
automotive accessories on your
Polaris ATV. Always install Polaris­approved (or equivalent) accessories
designed for ATV use.

59

OPERATION

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.

5. Turn the fuel valve off.

60

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

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

Engine idle speed is the only adjustment Polaris recommends that the
operator perform. Any other adjustments should be performed b y an
authorized Polaris dealer.

The vehicle compliance labels can be found on the frame tubing of the
vehicle.

Electromagnetic Interference

This spark ignition system complies with Canadian ICES-002.
This vehicle complies with the EMC requirements of European direc-

tives 97/24/EC and 2004/108/EC.

61

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 128.

Service and adjustments are important for proper vehicle operation. If
you're not familiar with safe service and adjustment procedures, have a
qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average
riding conditions and an average vehicle speed of approximately 10
miles per hour. Vehicles subjected to severe use must be inspected and
serviced more frequently.

Severe Use Definition

• 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.

62

MAINTENANCE

WARNING

Periodic Maintenance Chart

Improperly performing the procedures marked with a  could result in
component failure and cause an accident, which may result in serious injury or
death. Always have an authorized Polaris dealer perform these services.

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.

63

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 - Daily - Check level daily, change

X ADC fluid

(ADC models)

Headlight/taillight/
worklight

XEAir filter,

main element

Recoil housing - Weekly - Drain water as needed,

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

X

Q

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, add as

- Daily - Check operation; apply

- Weekly - Inspect; replace 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 45.

as needed

coolant every 2 years

needed

dielectric grease if replacing
lamps

check often if operating in wet
conditions

Remarks

64

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

X General

lubrication

Carburetor float
bowl

Q

Throttle Cable/

E

ETC Switch

Q

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

E

E Carburetor air

intake ducts/flange

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

Cooling system 50 H 6 M 1000 (1600) Inspect coolant strength

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

Q

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

E

Q

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

E

X Radiator

(if applicable)

X Cooling hoses

(if applicable)

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

Exhaust muffler/
pipe

Q

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

E

Q

Ignition timing 100 H 12 M 1000 (1600) Inspect

E

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) Drain bowl periodically and

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

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

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.

prior to storage

replace if necessary

replace if necessary

ing/air leaks

needed

seasonally; pressure test
system yearly

at one month

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

surfaces

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

Remarks

65

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)

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

Idle speed - Adjust as needed

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

when parts are replaced

Remarks

66

MAINTENANCE

Front Prop Shaft Yoke

Lubrication Guide

Check and lubricate all components at the intervals outlined in the Peri­odic Maintenance Chart beginning on page 62. Items not listed in the
chart should be lubricated at the General Lubrication interval.

The a-arms and lower control arms are lubricated at the factory, and no
additional lubrication will be needed. However, if these components are
subjected to severe use, grease zerks have been provided for additional
lubrication at the user's discretion.

Item Lube Capacity at

Inspection Procedure

Fluid Change

Engine Oil Polaris Premium 4

Brake Fluid DOT 4 Only --- Maintain level between fill

Transmission Oil Polaris AGL

Demand Drive
Fluid
(Front Gearcase)

ADC Fluid Polaris ADC Fluid --- Maintain level between fill

Front Prop Shaft
Yoke

Synthetic 0W40

Synthetic
Gearcase Lube

Demand Drive LT
Premium Fluid

Polaris Premium
U-Joint Lube

2 qt. (1.9 l) Maintain level in safe range

32 oz. (948 ml) Maintain level at bottom of fill

9 oz. (265 ml) Maintain level at bottom of fill

--- Grease fittings (3 pumps

on dipstick. See page 69.

lines. See page 28.

hole threads. See page 73.

hole threads. See page 74.

lines. See page 76.

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

67

MAINTENANCE

Engine Oil

Oil Recommendations

Polaris Premium 4 All Season synthetic engine oil has been specially
formulated for use in Polaris 4-cycle engines. It's a fully synthetic, high
performance, multi-viscosity oil designed to provide the ultimate in
lubrication performance and protection. See page 119 for the part num­bers of Polaris products.

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

Although Polaris Premium 4 is the only oil recommended for use in this
engine, use of any API certified SH oil is allowable as long as it's 0W-

40. Oil may need to be changed more frequently if Polaris Premium 4 is

not used. Follow the manufacturer's recommendations for ambient tem­perature operation.

NOTICE: Mixing brands or using a non-recommended oil may cause serious

engine damage. Always use the recommended oil. Never substitute
or mix oil brands.

68

Engine Oil

Dipstick

Safe

Add Oil

{

Safe Range

Oil Level

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

A rising oil level between checks in
cool weather driving can indicate
contaminants such as gas or mois­ture collecting in the crankcase. If
the oil level is over the full/safe
mark, change the oil immediately.

1. Position the vehicle on a level

surface.

2. Start the engine. Allow it to idle

for 20-30 seconds. Stop the
engine.

3. Remove the dipstick. Wipe it

dry with a clean cloth.

4. Reinstall the dipstick com-

pletely.

5. Remove the dipstick and check

the oil level. Maintain the oil
level in the safe range. Do not
overfill.

MAINTENANCE

69

MAINTENANCE

Drain

Plug

Screen

Fitting

New Sealing Washer

Alignment Mark

Oil and Filter Change

Always change the oil and filter at the intervals outlined in the Periodic
Maintenance Chart beginning on page 62. 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.

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

7. Install a new sealing washer on

the drain plug. The sealing sur­faces on drain plug and crank­case should be clean and free of
burrs, nicks or scratches.

8. Reinstall the drain plug. Torque

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

9. Disconnect the lower oil deliv-

ery hose and remove the screen
fitting from the oil tank. Clean
the fitting. The fitting threads must be sealed with LOCTITE PST

505 or PTFE seal tape.

10. Reinstall the screen fitting and rotate the fitting clockwise a mini-

mum 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.
Do not over-tighten. Maximum torque for the screen fitting is 25 ft.
lbs. (34 Nm).

11. Reattach the oil line.

70

MAINTENANCE

Oil and Filter Change

12. Place shop towels beneath the oil

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

13. Using a clean dry cloth, clean the

filter sealing surface on the crank­case.

14. Lubricate the o-ring on the new

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

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

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

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

To drain, remove the drain plug on the lower right side of the crank­case. The sealing surfaces on the drain plug and crankcase should
be clean and free of burrs, nicks or scratches.

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.

Tip: 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 72. 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.

71

MAINTENANCE

Clamp

Pressure

Relief Slit

Tank

2"

(5 cm)

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.

Tip: If you do not hear air, the line has not bled. Repeat the priming procedure.

72

MAINTENANCE

Drain Plug

Fill Plug

Fill Plug

Transmission Oil

Always check and change the transmission oil at the intervals outlined
in the Periodic Maintenance Chart beginning on page 62. 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
119 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. T orque

to 22 ft. lbs. (30 Nm).

5. Reinstall the footwell.

73

MAINTENANCE

Drain

Plug

Drain Plug

Fill

Plug

Fill Level

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. Dispose of used oil properly.

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 62. We rec­ommend the use of Demand Drive LT Premium Fluid. Use of other
fluids may result in improper operation of components. See page 119 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.

74

Demand Drive Capacity

Sportsman 500 9 oz. (265 ml)

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 74 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.

75

MAINTENANCE

ADC Fluid Reservoir

Active Descent Control (ADC) Fluid

If your vehicle is equipped with Active Descent Control, there are two
fluid levels that must be maintained (demand drive fluid and ADC
fluid). See page 74 for demand drive fluid maintenance. Check and
change the ADC fluid level at the intervals outlined in the Periodic
Maintenance Chart beginning on page 62. Maintain the fluid level
between the minimum and maximum marks on the reservoir. We recom­mend the use of Polaris ADC Fluid. See page 119 for the part numbers
of Polaris products.

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

1. Open the front box cover and pull

2. View the fluid level in the reser-

3. If the level is below the minimum

4. Reinstall the cap. Secure the access

the hydraulic system.

open the access door.

voir.

mark, remove the cap and add the
recommended fluid.

door. Secure the box cover .

76

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.
Debris in the reservoir may result in inadequate bleeding and
reduced performance of the system.

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

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.

IMPORTANT: Close the bleeder valves before the reservoir fluid level drops
below the minimum fill line. Adding fluid to an empty resevoir 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

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

9. Reinstall the cap securely.

10. Clean up any drips or spills.

77

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.

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

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 119 for the part
numbers of Polaris products.

Always follow the manufacturer's mixing recommendations for the
freeze protection required in your area.

Recovery Bottle Coolant

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

1. Remove the left side panel.

See page 82.

2. Maintain the coolant level

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

3. Add coolant as needed.

78

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 dry, check the level
in the radiator. Add coolant as needed.

CAUTION! Escaping steam can cause 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

and pull open the access
door.

2. Remove the pressure cap.

3. Using a funnel, slowly add

coolant through the radia­tor filler neck.

4. Reinstall the pressure cap.

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

5. Secure the access door.

6. Secure the box cover.

79

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 lock­up, 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 28.

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 30.

80

MAINTENANCE

String

Stand

2

1

Toe Alignment

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.

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

1. 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. If available, you
may use a long straight­edge instead of string.

4. Measure the distance

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.

5. Repeat the measurement procedure on the other side o f the vehicle.

6. If you discover improper alignment, see your Polaris dealer for se r-

vice.

81

MAINTENANCE

Step 1 Step 2 Step 3

Screws

Rivets

Steering Assembly

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

Side Panel Removal

1. Remove the seat.

2. Grasp the rear of the side panel near the rear cab. With a firm
motion, pull the panel outward to disengage the side panel from the
grommet.

3. Pull the panel downward and rearward to remove it.

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.

82

MAINTENANCE

WARNING

1/8" (3 mm)

Tires

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. Always follow all tire maintenance
procedures as outlined in this manual and on the labels on the vehicle. Always
use original equipment size and type when replacing tires.

Refer to the specifications section beginning on page 120 for recom­mended tire type, size and pressure.

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.

WARNING! Do not service axle nuts that have a cotter pin installed. See your
Polaris dealer.

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.

83

MAINTENANCE

Cast Aluminum Steel

90 ft. lbs.
(122 Nm)

27 ft. lbs.

(37 Nm)

Tires

Wheel Installation

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.

WARNING! Loose nuts could cause a tire to come off during operation, which
could result in an accident or overturn. Always ensure that all nuts are torqued 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)

84

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. Install a new
main filter if needed.

6. Reinstall the filter into the air
box and tighten the clamp.
Do not over-tighten the clamp, as filter damage could occur.

7. Reinstall the air box cover and the seat.

85

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 82.

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. The filter is effective with the
arrow pointing in either direction.

NOTICE: Operation of your vehicle without a breather filter can cause engine

damage. Always reinstall the breather filter after removing it for
service.

86

Fuse Replacement

Fuse Panel

Fuses

5or61520 20

If the engine stops or will not
start, or if you experience
other electrical failures, a fuse
may need replacement.
Locate and correct any short
circuits that may have caused
the blown fuse, then replace
the fuse. Spare fuses are pro­vided in a compartment on
the top of the access door.

1. Open the front box cover.

2. Open the access door.

3. Remove the suspect fuse
from the fuse panel. If the
fuse is blown, install a
new fuse with the same
amperage.

4. Secure the access door.

5. Secure the box cover.

MAINTENANCE

87

MAINTENANCE

Lights

Poor lighting can result in reduced visibility when driving. Headlight
and taillight lenses become dirty during normal operation. Clean lights
frequently and replace burned out lamps promptly. Always make sure
lights are adjusted properly for best visibility.

Headlight Lamp Replacement

When servicing a halogen lamp, don't touch the lamp with bare fingers.
Oil from your skin leaves a residue, causing a hot spot that will shorten
the life of the lamp.

1. Remove the two screws on the lower front corners of the headlight
pod.

2. Remove the screw from the rear of the pod.

3. Lift the pod slightly while depressing the tabs at the rear of the pod.

4. Lift the pod cover and disconnect the speedometer harnesses from

the speedometer.

CAUTION! Hot components can cause burns to skin. Allow lamps to cool
before servicing.

5. Unplug the headlamp from the wiring harness. Be sure to pull on the

connector, not on the wiring.

6. Turn the lamp counterclockwise to remove it.

7. Apply dielectric grease to the socket and install the new lamp. Make

sure the tab on the lamp locates properly in the housing.

8. Reassemble the pod.

88

MAINTENANCE

25 ft.

(7.6 m)

2" (5 cm)

Phillips Screw

Lights

High Beam Adjustment

The headlight beam can be adjusted slightly upward or downward. Use
the following procedure to make the adjustment.

1. Position the vehicle on a level surface with the headlight approxi­mately 25 ft. (7.6 m) from a wall. Place the transmission in PARK.

2. Measure the distance from the floor to the center of the headlight

and make a mark on the wall at the same height.

3. Start the engine.Turn the headlight switch to high beam.

4. Observe the headlight aim on the wall. The most intense part of the

headlight beam should be two inches (5 cm) below the mark on the
wall. Include rider weight on the seat when measuring.

5. The adjustment knob is located on the right side of the headlight

pod. Adjust the beam to the desired position by turning the knob
either clockwise or counterclockwise.

Low Beam Adjustment

The low beam can be adjusted slightly
upward or downward.

1. Loosen the phillips screw located
at the rear of the headlamp.

2. Tilt the headlamp upward or

downward.

3. Tighten the screw.

89

MAINTENANCE

5 1/8"

(13 cm)

Lights

Headlight Housing Replacement

1. Remove the two screws on the lower front corners of the headlight
pod.

2. Lift the pod slightly while depressing the tabs at the rear of the pod.

3. Lift the pod cover and disconnect the speedometer harnesses from

the speedometer.

4. Unplug the headlamp from the wiring harness.

5. Use a small screwdriver to remove the o-rings from the headlight

mounting tabs.

6. Pull the headlight housing up to release it from the locking tabs.

7. Lift the adjusting knob up to remove it from the locking tabs.

8. Carefully pull the assembly up

and out of the pod.

9. Reverse the steps to install the

new housing and reassemble
the pod. The distance from the
headlamp parting line to the
end of the adjustment knob
stop is 5 1/8" (13 cm).

10. Adjust the headlight aim by

turning the adjusting knob.

90

MAINTENANCE

Harness

Connector

Lamp

Lights

Lower Headlamp Replacement

1. Turn the back of the headlight
harness counterclockwise and
pull the harness assembly away
from the headlight assembly.

2. Remove the headlamp and install

the new headlamp.

3. Reinstall the harness assembly

into the headlight assembly.

4. Turn the headlight harness clock-

wise to secure the headlamp.

Taillight/Brakelight/Worklight (if equipped) Lamp
Replacement

1. Remove the harness connector
from the back of the light
assembly.

2. Turn the lamp counterclock-

wise to remove it.

3. Apply dielectric grease to the

socket and install the new
lamp.

4. Reinstall the harness connec-

tor.

5. Test the light for proper operation.

91

MAINTENANCE

Spark Plugs

Spark Plug Recommendations

Refer to the specifications section beginning on page 120 for the recom­mended spark plug type and gap for your vehicle. Torque spark plugs to
specification.

NOTICE: Using non-recommended spark plugs can result in serious engine

Spark Plug Inspection

Spark plug condition is indicative of engine operation. Check the spark
plug firing end condition after the engine has been warmed up and the
vehicle has been driven at higher speeds. Immediately check the spark
plug for correct color . See page 93.

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

1. Rotate the spark plug cap 1/4 turn and pull it off the spark plug.

2. Using the special wrench provided in the tool pouch, rotate the

3. Reverse the procedure for spark plug installation. Torque to specifi-

damage. Always use Polaris-recommended spark plugs.

Plug Condition Torque Specification

New Spark Plug 9-11 ft. lbs. (12-15 Nm)

Previously Installed Spark Plug 17-20 ft. lbs. (23-27 Nm)

spark plug counterclockwise to remove it.

cation.

92

MAINTENANCE

Spark Plugs

Spark Plug Inspection

Normal Spark Plug

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

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

Wet Fouled Spark Plug

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

93

MAINTENANCE

Drain Screw

Vehicle Immersion

If your vehicle becomes immersed, major engine damage can resu lt if
the machine is not thoroughly inspected. T ake the vehicle to your dealer
before starting the engine. If it's impossible to take your ATV to a dealer
before starting it, follow the steps outlined below.

1. Move the ATV to dry land or at the very least, to water below the
footrests.

2. Check the air box. If water is present, dry the air box and replace the

filter with a new filter.

3. Turn the fuel valve off.

4. Remove the spark plug.

5. Loosen the carburetor drain

screw.

6. Turn the engine over several

times using the electric start.

7. Dry the spark plug. Reinstall the

plug or install a new plug

8. Tighten the carburetor drain

screw.

9. Turn the fuel valve on.

10. Attempt to start the engine. If

necessary, repeat the drying
procedure.

11. Take the ATV to your dealer for service as soon as possible,

whether you succeed in starting it or not.

12. If water has been ingested into the PVT, follow the procedure on

page 98 for drying out the PVT.

94

MAINTENANCE

WARNING

Exhaust

Outlet

Clean-Out Plug

Spark Arrestor

Failure to heed the following warnings while servicing the spark arrestor could
result in serious injury or death. Never run the engine in an enclosed area.
Remove any combustible materials from the area. Wear eye protection and
leather work gloves. Do not stand behind or in front of the vehicle while purging.
Never go under the vehicle while it's inclined.

The exhaust system can get extremely hot. Do not perform service on the spark
arrestor while the system is hot. Allow components to cool sufficiently before
proceeding.

Use the following procedure to periodically purge accumulated carbon
from the exhaust pipe/muffler.

1. Remove the arrestor clean-out
plug from the bottom of the
muffler.

2. Place the transmission in

PARK.

3. Start the engine.

4. Quickly squeeze and release

the throttle lever several times
to purge carbon from the system.

5. If carbon comes out of the exhaust, cover or plug the exhaust outlet.

Wear protective gloves.

6. Lightly tap on the exhaust pipe with a rubber mallet while repeating

step 4.

7. If particles are still suspected to be in the muffler , elev ate the rear of

the vehicle one foot (30 cm) higher than the front. Block the wheels.

8. Place the transmission in PARK. Lock the parking brake. Repeat

steps 4 to 6 until no more particles are expelled.

9. Stop the engine. Allow the arrestor to cool.

10. Reinstall the arrestor plug and remove the exhaust outlet cover or

plug.

95

MAINTENANCE

WARNING

PVT System

Failure to comply with the instructions in this warning can result in severe injury
or death.

Do not modify any component of the PVT system. Doing so may reduce its
strength so that a failure may occur at a high speed. The PVT system has been
precision balanced. Any modification will cause the system to be out of balance,
creating vibration and additional loads on components.

The PVT system rotates at high speeds, creating large amounts of force on
clutch components. Extensive engineering and testing has been conducted to
ensure the safety of this product. However, as the owner, you have the following
responsibilities to make sure this system remains safe:

• Always follow all recommended maintenance procedures. See your dealer as
outlined in the owner's manual.

• This PVT system is intended for use on Polaris products only. Do not install it
in any other product.

• Always make sure the PVT housing is securely in place during operation.

96

MAINTENANCE

PVT System

The basic operation of the Polaris PVT system is dependent on engine
speed and vehicle torque requirements. As engine speed increases, the
force exerted on the movable drive sheave by the flyweights also
increases. This, in turn, increases the amount of pinch applied to the
drive belt. Similarly, if the engine speed decreases, the amount of cen­trifugal force decreases, reducing the amount of belt pinch.

On Polaris ATVs, the approximate gear ratio difference between high
and low range is 1:2.25. This difference in gearing affects the operation
of the PVT, especially at speeds less than 7 MPH (11 km/h), due to the
system's dependence on engine speed.

For example, when operating at a ground speed of 3 MPH (5 km/h) in
low range, the engine speed would be around 3000 RPM. This is well
above the engagement speed of 1200 - 1400 RPM. However, in high
range at 3 MPH (5 km/h), the engine would be running at only 1500
RPM. Whenever operating this close to the engagement speed, the
engine may be running at a speed too low to provide the pinch needed to
prevent belt slip. Belt slip is responsible for creating the excessive heat
that destroys belts, wears clutch components and causes outer clutch
covers to fail.

The air temperature in the clutch cover is substantially reduced by using
low range while operating at low ground speeds. Reducing the tempera­ture inside the clutch cover greatly extends the life of the PVT compo­nents (belt, cover, etc.).

97