Polaris Sportsman 9922551 User Manual

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Page 1

Pantone 426c

Sportsman 500 Touring

International

2010 Owner's Manual

for Maintenance and Safety

Read this manual carefully.

It contains important safety information.

This is an adult vehicle only.

Operation is prohibited for those under 16 years of age.

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PASSENGER

UNDER

Pantone 426c

Before you operate or ride this vehicle, read the owner’s manual.

Lesen Sie die Bedienungsanleitung, bevor Sie dieses Fahrzeug bedienen oder fahren.

Antes de operar o conducir este vehículo, lea el Manual del propietario.

Lire le Manuel d’utilisation avant d’utiliser ou de conduire ce véhicule.

Prima di usare o guidare il veícolo, leggere il Manuale di istruzioni.

Lue aina käyttöohjekirja ennen tämän ajoneuvon käyttöä tai ajamista.

Antes de utilizar ou andar neste veículo, leia o Manual do proprietário.

Innan du hanterar eller kör detta fordon, läs Handboken.

For your nearest Polaris dealer, visit www.polarisindustries.com

Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 U.S.A.

Part No. 9922551 Rev 01 Printed in U.S.A.

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The text is printed on 100% recycled

with 40% post-consumer waste (PCW).

Page 4

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

• Victory Motorcycles Always follow the instructions and recommendations in this manual.

The 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. Please see your dealer for all of your service needs during (and after) the warranty period.

For more information about Polaris, visit us online at www.polarisindustries.com.

utility vehicles

Page 5

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

Copyright 2009 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.

Printed in U.S.A. 2010 SPORTSMAN 500 Touring International Owner’s Manual P/N 9922551

Page 6

TABLE OF CONTENTS

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

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

Features and Controls . . . . . . . . . . . . . . . . . . . 20

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Emission Control Systems . . . . . . . . . . . . . . . 60

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 118

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 120

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 121

Declaration of Conformity . . . . . . . . . . . . . . . 125

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 130

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

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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.

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INTRODUCTION

WARNING

Failure to follow the warnings in this manual can result in serious injury or death. This Polaris vehicle is not a toy and can be hazardous to operate. A collision or rollover can occur quickly, even during routine maneuvers, if you fail to take proper precautions.

Read and understand your owner's manual and all warnings before operating this Polaris vehicle.

Safety Training

When you purchased your new Polaris vehicle, your dealer offered a hands-on safety training course. You were also provided with printed materials that explain safe operating procedures. Review this information on a regular basis.

If you purchased a used Polaris vehicle from a party other than a Polaris dealer, please request free safety training from any authorized Polaris dealer.

Age Restrictions

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

Restrictions

This vehicle is approved for OFF-ROAD TOWING ONLY. Towing a trailer with this vehicle on public roads is prohibited. See your Polaris dealer about configuring the vehicle to be certified to tow a trailer onroad.

Equipment Modifications

The warranty on your Polaris vehicle may be terminated if any equipment has been added, or if any modifications have been made, that increase speed or power. The addition of certain accessories, including (but not limited to) mowers, blades, tires, sprayers and large racks may change vehicle handling. Use only Polaris-approved accessories. Know their function and effect on the vehicle.

Page 9

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: ___________________________________________________________

Page 10

SAFETY

WARNING

Failure to operate the vehicle 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.

Equipment Modifications

We strongly recommend that consumers do not install on a Polaris vehicle 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 vehicle is terminated if any equipment has been added to the vehicle, or if any modifications have been made to the vehicle, that increase its speed or power.

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.

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SAFETY

Helmet

Eye Protection

Gloves

Boots

Long Pants

Long

Sleeves

051039

0006.31

Safe Riding Gear

Always wear protective clothing to reduce the chance of injury.

Helmet

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.

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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.

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SAFETY

Rider Safety

Read and understand all warnings, cautions and operating procedures in this manual and on the safety labels before operating the vehicle.

Never operate this vehicle without proper instruction. Take a training course. Beginners should receive training from a certified instructor. Contact an authorized Polaris dealer or visit the Polaris web site at www.polarisindustries.com.

Never permit others to operate the vehicle unless they have read and understand this manual and all product labels, and have completed a certified safety training course.

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

Never allow anyone under 12 years of age to ride as a passenger on this 2-up vehicle.

Never carry more than one passenger on this 2-up vehicle.

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Rider Safety

Always wear an approved helmet that fits properly. Wear eye protection (goggles or face shield), gloves, boots, long sleeves and long pants.

Never consume alcohol or drugs before or while operating this vehicle.

Never operate at excessive speeds. Travel and turn at speeds appropriate for the terrain, visibility, operating conditions and your experience.

SAFETY

Never attempt jumps or other stunts.

Always inspect your vehicle before each use to verify that it's in safe operating condition. Follow the inspection and maintenance procedures outlined in this manual. See page 38.

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SAFETY

Rider Safety

Keep both hands on the handlebars. Keep both feet on the footrests.

A passenger should always be seated in the passenger seat with both feet on the footrests and both hands on the passenger grab handles at all times. The passenger should never hold on to the operator.

Always travel slowly when operating on unfamiliar terrain. Use extra caution.

Use caution when operating on rough, slippery or loose terrain.

Always follow the procedures outlined in this manual for turning. See page 43.

Never turn sharply at excessive speeds, which can lead to vehicle overturn.

If the vehicle has been involved in an accident, always have an authorized Polaris dealer inspect the entire vehicle for possible damage, including (but not limited to) brake, throttle and steering systems.

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Rider Safety

>15°

Always follow the procedures outlined in this manual for driving on hills. See page 46. Never operate on hills too steep for the vehicle or for your abilities. Practice on smaller hills before attempting larger hills. Avoid climbing hills steeper than 15°.

Always follow the procedures outlined in this manual for driving downhill and for braking on hills. See page 49.

Always follow the procedures outlined in this manual for crossing the side of a hill. See page 48.

Never attempt to turn the vehicle around on any hill until you've mastered (on level ground) the turning technique outlined in this manual.

SAFETY

Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never back down a hill. See page 50.

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SAFETY

Rider Safety

Always follow the procedures outlined in this manual for operating over obstacles. See page 55.

Always follow the procedures outlined in this manual for operating on slippery or loose surfaces. Use extra caution. Always avoid skidding or sliding. See page 54.

Always follow the procedures outlined in this manual for driving through water. Never drive through deep or fast-flowing water. See page

52.

Always follow the procedures outlined in this manual for driving in reverse. See page 57.

Page 18

Rider Safety

Always use the size and type of tires specified for your vehicle. Maintain the proper tire pressure.

Never modify the vehicle through improper installation or use of accessories.

Never exceed the stated load capacity for your vehicle. Cargo must be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for carrying cargo or towing. Allow a greater distance for braking.

SAFETY

Never operate the vehicle on a frozen body of water.

Page 19

SAFETY

Rider Safety

Operating on paved surfaces may affect the handling and control of the vehicle and could result in loss of control. Avoid sudden turns or swift movement of the handlebars.

Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting.

Always unlock the steering before starting the engine. See page 28.

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.

Hot components can cause serious burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.

For more information about safety, contact an authorized

Polaris dealer or visit the Polaris web site at

www.polarisindustries.com.

Page 20

SAFETY

General

Alert

Hill

Operation

Alert

Age 16

Alert

Safety Decals and Locations

Warning decals have been placed on the vehicle for your protection. Read and follow the instructions on each decal carefully. If a decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal.

The following pages repeat the information found on each decal.

General Alert (Multi-Lingual)

Before you operate or ride this vehicle, read the owner’s manual.

Hill Operation Alert

• Never operate this vehicle on HILLS

steeper than 15 degrees 15°.

• To prevent flip-over on hilly terrain,

when going up or down, use throttle and brakes gradually.

Page 21

SAFETY

Front Rack

Warning

Tire Pressure/

Load Alert

Clutch

Cover Alert

Rear Rack

Warning

Reverse Override

Alert

Safety Decals and Locations

Tire Pressure/Load Alert

TIRE PRESSURE IN PSI (KPa): FRONT 5 (34.5) REAR 5 (34.5) MAXIMUM WEIGHT CAPACITY 568 LBS. (258 kg) INCLUDES WEIGHT OF OPERATOR, PASSENGER, CARGO AND

ACCESSORIES. Read Owner's Manual for more detailed loading information.

Reverse Override Alert

Pushing reverse override button may cause sudden increases in power and traction if too much throttle is applied. Loss of control or forward flipover may result, especially in 4X4. See Owner's Manual.

Page 22

SAFETY

Safety Decals and Locations

Rack Warning, Front and Rear

WARNING 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. Maximum Rack Loads: Front 90 lbs. (41 kg) Rear 180 lbs. (82 kg)

Clutch Cover Alert

NO STEP

Page 23

FEATURES AND CONTROLS

Horn Switch

Hazard

Switch

Main Key Switch

Engine Stop Switch

Headlight

Switch

4X4

Switch

Turn Signal Switch

Mode/Reverse

Override Switch

Choke

Switches

Mode/Reverse Override Switch

Press the switch to toggle through the speedometer display modes (except in reverse). See page 32.

To gain additional power while operating in reverse, press the override switch before opening the throttle. This will cancel the reverse speed limit function.

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

switch is on.

Activating the override switch while the throttle is open can cause loss of control, resulting in severe injury or death. Do not activate the override switch while the throttle is open.

Page 24

FEATURES AND CONTROLS

Engine

Stop Switch

Light

Switch

Switches

Main Key Switch

End all electrical power to the vehicle.

LIGHTS ON position turns the headlights on.

Start the engine. The headlights are not on in this position.

After starting the engine, release the key switch to the POSITION LIGHTS ON position.

Do not attach a large key fob or key ring to the main switch. It may contact the gas tank cap when turning, causing an interruption to the electrical system and an unexpected engine shut-down during operation. This could result in serious injury or death.

Engine Stop Switch

The engine will not start or run when the switch is in the OFF position.

OFF

RUN

Light Switch

The lights do not operate unless the main key switch is on and the engine stop switch is in the RUN position.

High Beam

Low Beam

Page 25

FEATURES AND CONTROLS

4X4 Switch

Tu r n

Indicators

Hazard Warning

Switch

Switches

4X4 Switch

Use the 4X4 switch to engage 4X4 or 2X4. See page 30.

Hazard Warning Switch

Push the hazard warning switch to cause all turn

signal lights to flash simultaneously. Use this feature to alert others of an emergency or other situation requiring caution.

Page 26

FEATURES AND CONTROLS

Horn Switch

Turn Signal

Switch

Switches

Turn Signal Switch

Push the toggle switch either left or right to

activate the corresponding turn signal light. The indicator on the pod will also flash. Return the toggle to the center position and push it inward to end the signal.

Horn Switch

Press the horn switch to sound the horn.

Page 27

FEATURES AND CONTROLS

Electronic Throttle Control

Throttle Lever

Press the throttle lever to increase engine speed and vehicle movement. Release the lever to reduce engine speed and vehicle movement.

Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation. Check the lever for proper operation before starting the engine. Check occasionally during operation.

Do not start or operate the vehicle with sticking or improperly operating throttle controls. Contact your dealer for repair if throttle problems arise.

Mirrors

Use the mirrors to assist in traffic maneuvers. Always check and adjust the mirrors before driving the vehicle.

Electronic Throttle Control (ETC)

ETC causes the engine to stop if the throttle cable sticks in an open position when the operator releases the throttle lever.

The Electronic Throttle Control (ETC) stops the engine in the event of a throttle system malfunction. Do not modify the ETC system or replace it with other throttle mechanisms.

Page 28

FEATURES AND CONTROLS

Foot Brake

The all-wheel foot brake is located on the right footrest. The foot brake operates both front and rear brakes. Press the brake pedal down with your foot to apply the all-wheel brakes.

If the rear wheels begin to skid or slide while using the foot brake, reduce brake pressure.

Hand Brake Lever

The hand brake operates both front and rear brakes. Squeeze the brake lever toward the handlebar to apply the all-wheel brakes.

If the rear wheels begin to skid or slide while using the brake, reduce lever pressure.

Aggressively applying the brakes when backing down a hill may cause rear tipover. Aggressively applying the brakes while moving forward may cause the rear wheels to skid and result in loss of control.

Read this owner's manual and understand the operation of all brake systems on this vehicle. Always use caution whenever applying the brakes.

Page 29

FEATURES AND CONTROLS

Parking Brake

Locking the Parking Brake

1. Place the transmission in PARK.

2. Squeeze the brake lever toward the

handlebar.

3. Push the parking brake lock forward to

engage the lock. Release the brake lever.

4. To release the parking brake lock,

squeeze and release the brake lever.

Operating the vehicle while the parking brake is engaged could result in an accident and serious injury or death. Always release the parking brake lock before operating.

Page 30

FEATURES AND CONTROLS

Recoil

Starter

Handle

OFF

Recoil Starter (if equipped)

If the battery is too weak to start the engine, use the recoil starter. Follow the starting procedures on page 39, cranking the engine with the recoil starter instead of the main key switch.

1. Grasp the recoil starter rope

handle tightly.

2. Pull slightly until the starter mechanism engages.

3. Pull the rope abruptly to start the engine.

Extending the recoil starter rope until it stops can cause damage to the recoil assembly.

If the starter rope handle is not seated properly, water may enter the recoil housing and damage components.

Choke

The choke assists in starting a cold engine. Refer to the engine starting procedure on page 39 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.

Page 31

FEATURES AND CONTROLS

Fuel Tank

Cap

Steering Lock

Lock the steering to prevent unauthorized use or theft of the vehicle.

1. Turn the handlebars to the full

right position.

Tip: The handlebars may also be

locked in the full left position.

2. Insert the steering lock key and

turn it clockwise.

3. Remove the key. Place the

steering lock keys in a safe place. The lock must be replaced if the keys are lost.

4. Reverse the procedure to unlock the steering.

The handlebars are locked in the fully turned position when the steering is locked. Always unlock the steering before starting the engine.

Fuel Tank Cap

Remove the fuel tank cap to add fuel to the fuel tank. Use either leaded or unleaded gasoline with a minimum pump octane of 87. Do not use fuel

with ethanol content greater than 10 percent, such as 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.

Page 32

FEATURES AND CONTROLS

Gear

Selector

Latch

Automatic Transmission Gear Selector

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

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

Whenever the vehicle is left unattended, always place the transmission in PARK. The transmission is locked when it’s in PARK.

NOTICE: Shifting gears with the engine speed above idle or while the vehicle is

To shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear. See your dealer if you experience any shifting problems.

Passenger Seat

Always make sure the passenger seat is installed and securely latched before operating with a passenger. Test the seat latch by attempting to pull the seat upward.

If the latch is not working properly, do not allow a passenger to ride the vehicle. See your Polaris dealer for service.

To remove the seat, pull the latch loop at the rear of the seat. Pull the seat upward to remove it from the vehicle.

To reinstall the seat, make sure the rubber feet at the base of the seat are positioned in the rear rack. Press down firmly on the seat pad until the latch clicks

moving could cause transmission damage.

Page 33

FEATURES AND CONTROLS

All Wheel Drive (4X4) System

4X4

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

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

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

on. See page 20.

2X4

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

Page 34

FEATURES AND CONTROLS

All Wheel Drive (4X4) System

Engaging 4X4

The 4X4 switch may be turned on or off while the vehicle is moving. 4X4 will not engage until engine speed is below 3100 RPM. 4X4 remains engaged until the switch is turned off. There is no limit to the length of time the vehicle may remain in 4X4.

If the switch is turned off while the demand drive unit is engaged, it will not disengage until the rear wheels regain traction. Engage 4X4 before getting into situations where maximum traction is needed. If the rear wheels are spinning, release the throttle before switching to 4X4.

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

Page 35

FEATURES AND CONTROLS

Rider

Information

Center

Speedometer

Needle

Speedometer

Instrument Cluster

The instrument cluster senses vehicle speed from the transmission. The instrument cluster measures distance in miles or kilometers, as well as hours of operation. It also includes a reverse speed limiter function that limits the vehicle's speed to approximately 11-14 km/h. Refer to page 20 for additional information.

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

High water pressure may damage vehicle components. Wash the vehicle 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.

Page 36

FEATURES AND CONTROLS

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 vehicle 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. 4X4 Indicator - This

indicator illuminates when the 4X4 switch is on 4X4.

3. Engine Hour Display Indicator

4. Service Interval/Diagnostic Mode Indicator

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

that the vehicle 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

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

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

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

poses. The word HOT displays if the engine overheats. Do not operate the vehicle if this warning appears. Serious engine damage could result.

9. Mode Indicator

Page 37

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 20.

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

Odometer Mode

The odometer records the miles or kilometers traveled by the vehicle.

Trip Meter Mode

The trip meter records the miles or kilometers traveled by the vehicle 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.

Tip: 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.

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

changes in humidity, temperature and elevation.

Page 38

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.

Battery Voltage Screen

View this screen to check battery voltage level.

Tachometer Screen

View the tachometer to check engine speed.

4X4 Diagnostic Screen

The gauge indicates whether or not current is flowing through the 4X4 coil (only on models with switchable 4X4). 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.

Page 39

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

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.

The service interval is programmed at 50 hours at the factory. 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. If you scroll past the intended number, press and hold the button until the hours cycle back to zero.

5. 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.

Page 40

OPERATION

Break-In Period

The break-in period for your new Polaris vehicle 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 will increase the life and performance of your vehicle more than 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.

Do not operate at full throttle or high speeds for extended periods during the first three hours of use.

Engine and Drivetrain Break-in

1. Fill the fuel tank with the recommended fuel. See page 28.

2. Check the engine oil level. See page 66. Add oil if necessary.

3. Select an open area that allows room to familiarize yourself with

vehicle operation and handling.

4. Drive slowly. 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 38.

6. Pull only light loads.

7. Change the oil and filter at one month.

PVT Break-in (Clutches/Belt)

Break in the clutches and belt by operating at slower speeds during the break-in period as recommended. Pull only light loads. Avoid aggressive acceleration and high speed operation during the break-in period.

Page 41

OPERATION

Pre-Ride Checklist

Item Remarks Page

Hand brake/lever travel Ensure proper operation 81

Foot brake Ensure proper operation 81

Brake fluid Ensure proper level 81

Passenger seat latch Ensure latch is secure 29

Front suspension Inspect, lubricate if necessary 65

Rear suspension Inspect, lubricate if necessary 65

Steering/steering lock Unlock the steering; ensure free oper-

Steering Ensure free operation -

Tires Inspect condition and pressure 87

Wheels/fasteners Inspect, ensure fastener tightness 87

Frame nuts, bolts, fasteners Inspect, ensure tightness -

Fuel and oil Ensure proper levels 28

Coolant level (if applicable) Ensure proper level 76

Coolant hoses (if applicable) Inspect for leaks -

Throttle Ensure proper operation 24

Indicator lights/switches Ensure operation 20

Engine stop switch Ensure proper operation 21

Mirrors Adjust for best side/rear vision 24

Air filter, pre-filter Inspect, clean 90

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

ation

tric grease when lamp is replaced

protective clothing

Page 42

OPERATION

Ten si on

Adjusting Nut

Starting the Engine

Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area.

Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating.

1. Position the vehicle on a level

surface.

2. Place the transmission in

PAR K.

3. Turn the fuel valve on.

4. Sit on the vehicle.

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

is in gear and the brake is not engaged.

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

choke can cause the spark plug to become wet fouled.

6. If the engine is cold, pull the

choke knob out until it stops.

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.

7. If the knob doesn't stay where

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

Page 43

OPERATION

Starting the Engine

8. Move the engine stop switch to

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

9. Turn the ignition key past the POSITION

LIGHTS ON position to engage the starter. Activate the starter for a maximum of five seconds, releasing the key when the engine starts.

10. If the engine does not start, release the

starter and wait five seconds.

11. Repeat steps 9 and 10 until the engine

starts.

Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating the vehicle.

12. If a warm engine has cooled to a point where it does not readily

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

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

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

Page 44

OPERATION

Cold Weather Operation

Internal engine condensation increases as outside temperatures decrease. If the vehicle is used year-round, check the oil level frequently. A rising oil level could indicate condensation in the bottom of the oil tank, which can lead to engine damage. Any condensation must be drained.

Always operate the engine long enough to reach operating temperature, which reduces condensation. See your Polaris dealer for engine heater kits, which provide quicker warm-ups and easier starting in cold weather.

PVT Operation

When To Use Low Range and High Range

Condition Range to Use

Operating at speeds less than 11 km/h Low

Towing heavy loads Low

Operating in rough or rugged terrain Low

Operating at speeds greater than 11 km/h High

Page 45

OPERATION

Driving Procedures

1. Wear protective riding gear. See page 8.

2. Perform the pre-ride inspection. See page 38.

3. Place the transmission in PARK.

4. Mount the vehicle from the left side.

5. Sit upright. Keep your feet on the footrests. Keep both hands on the

handlebars.

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

7. Apply the brakes.

8. Shift the transmission into gear.

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

10. Release the brakes.

11. Slowly squeeze the throttle lever toward the handlebar to begin

driving.

12. Drive slowly. Practice maneuvering and using the throttle and

brakes on level surfaces.

Page 46

OPERATION

Turning the Vehicle

1. Before turning, activate a turn sig-

nal to alert others of your intentions. Activate the left signal before a left turn. Activate the right signal before a right turn.

2. 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. Use the same leaning technique for turning in reverse.

3. Never turn quickly when carrying

a passenger or cargo.

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

faster speeds.

Always follow the procedures outlined in this manual for turning. Never turn sharply at excessive speeds, which can lead to vehicle overturn.

Page 47

OPERATION

Driving with a Passenger

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

Never allow anyone under 12 years of age to ride as a passenger on this 2-up vehicle.

Never carry more than one passenger on this 2-up vehicle.

1. Make sure the passenger is

at least 12 years of age and is tall enough to comfortably reach the footrests and grab handles.

2. Make sure the passenger is

wearing appropriate riding gear, including an approved helmet with a rigid chin guard. See page 8.

3. Perform the pre-ride

inspection. See page 38.

4. Always make sure the

passenger seat is installed and securely latched before operating with a passenger.

5. Place the transmission in PARK.

Page 48

OPERATION

Driving with a Passenger

6. Mount the vehicle from the left side.

7. After the operator is seated, the passenger should mount the vehicle

from the left side.

Allow a passenger to ride only in the approved passenger seat with both feet on the footrests and both hands on the passenger grab handles at all times. The passenger should never hold on to the operator.

8. Drive slowly. Control may be more difficult with a passenger on

board. Allow more time and distance for braking.

9. Avoid unexpected or aggressive maneuvers that could cause a pas-

senger to fall from the vehicle.

10. Do not cross a hillside with a passenger on board. See page 48.

11. Never secure a passenger to the vehicle or to the operator with a

belt, rope or similar device.

12. Make sure the passenger understands the importance of "active

riding." When hill-climbing or performing maneuvers, a passenger should shift body weight in the same manner in which the driver shifts body weight. For example, the passenger should lean to the inside of a turn along with the operator and should always lean uphill when climbing and descending hills.

Page 49

OPERATION

15° Maximum

Driving Uphill

Whenever traveling uphill, follow these precautions:

1. Avoid steep hills (15° maximum).

2. Avoid hills with slippery or loose surfaces.

3. Keep both feet on the footrests.

4. Shift body weight uphill.

5. Drive straight uphill.

6. Proceed at a steady rate of speed to avoid stalling.

7. Be alert. Be prepared to take emergency action. This may include

dismounting quickly.

8. Never open the throttle suddenly or make sudden gear changes.

9. Never go over the top of a hill at high speed.

Page 50

OPERATION

>15°

Driving Uphill

If all forward speed is lost:

Keep your weight uphill.

If the vehicle begins rolling downhill, never apply engine power. Never apply the brakes aggressively while rolling backwards.

1. Apply the brakes gradually.

2. When fully stopped, lock the hydraulic parking brake.

3. A passenger should dismount first.The operator should dismount

last. Dismount on the uphill side, or on the left side if the vehicle is pointed straight uphill.

4. Use the K-turn to turn around. See page 50.

Always follow the procedures outlined in this manual for climbing hills. Avoid climbing hills steeper than 15°.

Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never back down a hill.

Page 51

OPERATION

Driving on a Sidehill (Sidehilling)

Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is necessary, follow these precautions:

1. Slow down.

2. Avoid hills with slippery or loose surfaces.

3. Avoid crossing the sides of steep hills.

4. Do not cross a hillside with a passenger on board. Ask the passenger

to dismount and walk across the hillside.

5. Shift your weight uphill.

6. Keep your feet on the footrests.

7. Steer slightly into the hill.

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

possible, or dismount on the uphill side immediately!

Always follow the procedures outlined in this manual for crossing the side of a hill.

Never attempt to turn the vehicle around on any hill until you've mastered (on level ground) the turning technique outlined in this manual.

Page 52

Driving Downhill

15° Maximum

When driving downhill, follow these precautions:

1. Avoid hills with slippery or

loose surfaces.

2. Never drive downhill at high

speed. Slow down.

3. Drive straight downhill.

Avoid driving downhill at an angle, which can cause the vehicle to pitch sharply to one side.

4. Shift your weight rearward.

5. Apply the brakes slightly to aid in slowing.

Always follow the procedures outlined in this manual for driving downhill and for braking on hills.

OPERATION

Never operate at excessive speeds. Travel and turn at speeds appropriate for the terrain, visibility, operating conditions and your experience.

Page 53

OPERATION

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 the vehicle. Keep your weight uphill.

2. Lock the hydraulic parking brake.

3. Leave the transmission in forward gear. Turn the engine off.

4. A passenger should dismount first.The operator should dismount

last. Dismount on the uphill side, or on the left side if the vehicle is pointed straight uphill.

5. Stay uphill of the vehicle and turn the handlebars full left.

6. Squeeze the brake lever to release the parking brake.

7. Slowly release the brake lever and allow the vehicle to roll around

to your right until it's pointing across the hill or slightly downward.

Page 54

OPERATION

>15°

Turning Around on a Hill (K-Turn)

8. Lock the hydraulic parking brake.

9. Remount from the uphill side. Keep your weight uphill. A passenger

should not remount until the vehicle returns to level ground.

10. Apply the foot brake.

11. With the transmission still in forward, start the engine.

12. Squeeze and release the brake lever to release the parking brake.

13. Release the foot brake and drive slowly downhill. Control speed

with either the hand or foot brake until the vehicle is on level ground.

Always follow the procedures outlined in this manual for climbing hills. Avoid climbing hills steeper than 15°.

Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never back down a hill.

Page 55

OPERATION

Maximum

Depth

Driving Through Water

Follow these procedures when driving through water:

1. Check water depth and current before crossing.

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

3. Drive slowly. Avoid rocks and obstacles.

4. Avoid operating in water deeper than the bottom of the footrests. If

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

5. Wet brakes may have reduced stopping ability. Dry the brake pads

by driving slowly and applying the brakes lightly several times until braking action is normal.

Page 56

OPERATION

Driving Through Water

If your vehicle becomes fully immersed, and it's impossible to take it to a dealer before starting it, follow the steps described on page 98. Have the vehicle serviced by your dealer promptly.

Always follow the procedures outlined in this manual for driving through water. Never drive through deep or fast-flowing water.

If the vehicle stops while fully submerged, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine.

Page 57

OPERATION

Driving on Slippery Surfaces

Whenever driving on slippery or loose surfaces such as wet trails, gravel, snow or ice, follow these precautions:

1. Slow down before driving

onto slippery surfaces.

2. Engage 4X4 before wheels

begin to lose traction.

3. Be alert.

4. Watch the trail.

5. Avoid quick, sharp turns.

6. Correct a skid by turning the

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

7. Never apply the brakes during a skid.

Always follow the procedures outlined in this manual for operating on slippery or loose surfaces. Use extra caution. Always avoid skidding or sliding.

Severe damage to drive train may occur if 4X4 is engaged while the wheels are spinning. Engage 4X4 when the wheels have traction.

Page 58

OPERATION

Driving Over Obstacles

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

2. Be alert. Watch the terrain. Use extra caution.

3. Never operate over large obstacles.

4. Avoid hazards such as logs, rocks and low branches.

5. Always have a passenger dismount before operating over an obsta-

cle.

Always follow the procedures outlined in this manual for operating over obstacles.

Page 59

OPERATION

Parking on an Incline

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

1. Stop the engine.

2. Place the transmission in PARK.

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

4. Turn the fuel valve off.

Page 60

OPERATION

Driving in Reverse

Follow these precautions when operating in reverse:

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

backing. Be aware that a passenger can obstruct your view.

2. Avoid backing downhill.

3. Drive slowly. Apply the brakes lightly for stopping.

4. Avoid turning at sharp angles.

5. Never open the throttle suddenly.

6. Do not use the override switch unless additional power is required

for vehicle movement. Use with caution.

Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust, resulting in engine popping and/or engine damage.

Always follow the procedures outlined in this manual for driving in reverse.

Page 61

OPERATION

Hauling Cargo

Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo.

• Read and understand the load distribution warnings listed on the vehicle

warning labels.

• Never exceed the stated load capacity for this vehicle.

• Never carry cargo on the rear rack when operating the vehicle in the 2-up

mode with a passenger.

• REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING

WHEN HAULING CARGO OR TOWING. Use extreme caution when applying brakes. Avoid situations that require backing downhill.

• When operating over rough or hilly terrain, reduce speed, cargo and towed

load to maintain stable driving conditions.

• DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the

front rack.

• CARRY LOADS AS LOW ON THE RACK AS POSSIBLE. Carrying a load high

on the rack raises the center of gravity of the vehicle and creates a less stable operating condition. Reduce load weight when cargo is high. Secure offcentered loads that cannot be centered and operate with extra caution.

• CARRYING A LOAD on only one rack may cause the vehicle to overturn. Split

the load between the front rack and rear rack, with 1/3 in the front and 2/3 in the back. Do not exceed load capacities. See specifications beginning on page

118.

• 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.

• 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.

• TOWING is approved OFF-ROAD ONLY. Towing a trailer on public roads is

prohibited.

• TOWING SPEED should never exceed 16 km/h. Never exceed 8 km/h when

towing loads in rough terrain, while cornering, or while ascending or descending hills.

Page 62

OPERATION

1/3

2/3

Maximum

17 cm

Hauling Cargo

Towing Loads

Towing is approved OFF-ROAD ONLY. Towing a trailer on public roads is prohibited. See your Polaris dealer about configuring the vehicle to be certified to tow a trailer on-road. Do not tow any trailer on a grade steeper than 15°.

Always attach a towed load to the hitch point. If towing a load, reduce rear rack cargo weight by the amount of tongue weight.

• The combination of rear rack cargo weight and tongue weight must

not exceed the rear rack capacity.

• The total load (operator, passenger, accessories, cargo and weight on

hitch) must not exceed the maximum weight capacity of the vehicle.

Using an improper hitch or exceeding the maximum tongue weight capacity can result in serious damage to the vehicle and will void your warranty. Never install a hitch longer than 17 cm. Never install automotive accessories on your Polaris vehicle. Always install Polaris-approved (or equivalent) accessories designed for use on the Polaris vehicle.

Page 63

EMISSION CONTROL SYSTEMS

Noise Emission Control System

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

Spark Arrestor

Your Polaris vehicle has a spark arrestor that was designed for on-road and off-road operation. It is required that this spark arrestor remain installed and functional when the vehicle is operated.

Exhaust Emission Control System

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

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

Electromagnetic Interference

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

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

Page 64

MAINTENANCE

Periodic Maintenance Chart

Maintenance intervals in the following chart are based upon average riding conditions. Vehicles subjected to severe use must be inspected and serviced more frequently.

The programmable service interval mode on the instrument cluster will help determine when maintenance service is due. See page 32.

Record maintenance and service in the Maintenance Log beginning on page 130.

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.

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.

Page 65

MAINTENANCE

Periodic Maintenance Chart

Maintenance Chart Key

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

E Emission-related service

Q Have an authorized Polaris dealer perform these services.

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

Perform all services at whichever maintenance interval is reached first.

Item Maintenance Interval

Steering - Pre-Ride - Make adjustments as need

Front suspension - Pre-Ride -

Rear suspension - Pre-Ride -

Tires - Pre-Ride -

Brake fluid level - Pre-Ride -

Brake lever - Pre-Ride -

Foot brake - Pre-Ride -

Brake system - Pre-Ride -

Passenger seat latch

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

Headlight/taillight - Daily - Check operation; apply

(whichever comes first)

Hours Calendar Kilometers

ed. See Pre-Ride Checklist on page 38.

-Pre-Ride -

as needed

- Daily - Drain deposits when visible

coolant every 2 years

dielectric grease if replacing lamps

Remarks

Page 66

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

XEAir filter,

main element

Recoil housing (if equipped)

Brake pad wear 10 Monthly 160 Inspect periodically

Battery 20 Monthly 320 Check terminals; clean; test

X Demand drive fluid 25 Monthly 400 Inspect level; change yearly X Rear gearcase oil

(if equipped)

X Transmission oil 25 Monthly 400 Inspect level; change yearly XEEngine breather

filter (if equipped)

X Engine oil change

(break-in)

X General

lubrication

Carburetor float bowl

Shift linkage 50 6 M 800 Inspect, lubricate, adjust

Steering 50 6 M 800 Lubricate

X Front suspension 50 6 M 800 Lubricate X Rear suspension 50 6 M 800 Lubricate

Throttle cable/

ETC switch

(whichever comes first)

Hours Calendar Kilometers

- Weekly - Inspect; replace as needed

- Weekly - Drain water as needed,

25 Monthly 400 Inspect level; change yearly

25 Monthly 400 Inspect; clean if needed

- 1 M - Perform a break-in oil change

50 3 M 800 Lubricate all fittings, pivots,

50 6 M 800 Drain bowl periodically and

50 6 M 800 Inspect; adjust; lubricate;

check often if operating in wet conditions

at one month

cables, etc.

prior to storage

replace if necessary

Remarks

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

E Carburetor air

intake ducts/flange

Drive belt 50 6 M 800 Inspect; adjust; replace as

Cooling system 50 6 M 1600 Inspect coolant strength

X Engine oil change 100 6 M 1600 Perform a break-in oil change

X Oil filter change 100 6 M 1600 Replace with oil change X Oil tank vent hose

(if equipped)

50 6 M 800 Inspect duct for proper seal-

100 6 M 1600 Inspect routing, condition

replace if necessary

ing/air leaks

needed

seasonally; pressure test system yearly

at one month

Page 67

MAINTENANCE

Periodic Maintenance Chart

Item Maintenance Interval

Valve clearance 100 12 M 1600 Inspect; adjust

Fuel system/filter 100 12 M 1600 Check for leaks at tank cap,

X Radiator 100 12 M 1600 Inspect; clean external

X Cooling hoses 100 12 M 1600 Inspect for leaks X Engine mounts 100 12 M 1600 Inspect

Exhaust muffler/ pipe

Spark plug 100 12 M 1600 Inspect; replace as needed

X Wiring 100 12 M 1600 Inspect for wear, routing,

Clutches (drive and driven)

Front wheel bearings

Brake fluid 200 24 M 3200 Change every two years

Fuel filter 200 24 M 3200 Replace every 2 years, more

Spark arrestor 300 36 M 4800 Clean out

Idle speed - Adjust as needed

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 Kilometers

lines, fuel valve, filter, pump, carburetor; replace lines every 2 years

surfaces

100 12 M 1600 Inspect

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

100 12 M 1600 Inspect; clean; replace worn

100 12 M 1600 Inspect; replace as needed

parts

often under severe use

when parts are replaced

Remarks

Page 68

MAINTENANCE

Front Prop Shaft Yoke

Lubrication Guide

Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 61. Items not listed in the chart should be lubricated at the General Lubrication interval.

Tip: The a-arms and upper 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

Engine Oil PS-4 PLUS Performance

Brake Fluid DOT 4 Only --- See page 78.

Transmission Oil Polaris AGL Synthetic

Demand Drive Fluid (Front Gearcase)

Front Prop Shaft Yoke

Synthetic 2W-50

Gearcase Lube

Demand Drive Plus Fluid 9 oz. (265 ml) See page 74.

Polaris Premium U-Joint Lube

Fluid Change

2 qt. (1.9 l) See page 66.

32 oz. (948 ml) See page 72.

--- Grease fittings (3

Method

pumps maximum) every 800 km, before long periods of storage, or after pressure washing or submerging.

Page 69

MAINTENANCE

Engine Oil

Oil Recommendations

Always change the oil filter whenever changing oil. Polaris recommends the use of Polaris PS-4 PLUS Performance Syn-

thetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if Polaris oil is not used. Always use 2W-50 oil. Follow the manufacturer's recommendations for ambient temperature operation

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

Oil Specifications

Lubricant Capacity Drain Plug Torque

PS-4 PLUS Performance

Synthetic 2W-50 4-Cycle Oil

1.9 liters 19-23 N-m

Page 70

Engine Oil

Dipstick

Safe

Add Oil

Safe Range

{

Oil Level

1. Position the vehicle on a level

surface.

2. Place the transmission in PARK.

3. Start the engine. Allow it to idle

for 30 seconds.

4. Stop the engine.

5. Remove the dipstick.

Wipe it dry with a clean cloth.

6. Reinstall the dipstick

completely.

MAINTENANCE

7. Remove the dipstick and check the oil level. Add oil as needed.

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

8. Reinstall the dipstick.

Page 71

MAINTENANCE

Drain

Plug

New Sealing Washer

Screen

Fitting

Engine Oil

Oil and Filter Change

Hot oil may result in serious burns. Do not allow hot oil to contact skin.

1. Position the vehicle on a level

surface.

2. Place the transmission in PARK.

3. Start the engine. Allow it to idle

for 30 seconds.

4. Stop the engine.

5. Clean the area

around the drain plug.

6. Place a drain pan

under the oil tank.

7. Remove the drain

plug.

8. Drain the oil.

9. Clean the drain plug. Reinstall the drain

plug with a new sealing washer.

10. Torque to specification. See page 66.

Page 72

MAINTENANCE

Alignment Mark

Engine Oil

Oil and Filter Change

11. Disconnect the lower oil deliv-

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

Tip: The fitting threads must be sealed

with LOCTITE PST 505 or PTFE seal tape.

12. Reinstall the screen fitting and

rotate the fitting clockwise a minimum of 2 1/2 turns into the tank threads. Continue to rotate the fitting until the nipple of the fitting aligns with the mark on the tank. Do not over-tighten. Maximum torque for the screen fitting is 34 N-m.

13. Reattach the oil line.

14. Place towels under the oil filter.

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

15. Clean the filter sealing area on the

crankcase.

16. Lubricate the filter o-ring. Check to make

sure the o-ring is in good condition.

17. Install the new oil filter. After the filter

contacts the crankcase surface, turn it 1/2 turn by hand.

18. 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.

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

free of burrs, nicks or scratches.

19. Reinstall the drain plug. Torque to specification. See page 66.

Page 73

MAINTENANCE

Safe

Add Oil

Safe Range

{

Engine Oil

Oil and Filter Change

20. Remove the dipstick.

21. Add 1.9 liters of recommended

oil. If the sump is not drained, add about 1.6 liters initially.

22. Reinstall the dipstick.

23. Place the transmission in PARK.

24. Prime the oil pump using the procedure

on page 71.

25. Stop the engine. Check for oil leaks.

26. Check the oil level.

Add oil as needed. Maintain the oil level in the safe range. Do not overfill.

27. Reinstall the dipstick.

28. Discard used oil and

filter properly.

Page 74

MAINTENANCE

Clamp

Pressure

Relief Slit

Tank

5 cm

Engine Oil

Oil and Filter Change

Oil Pump Priming

This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected.

1. Clamp the vent line 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. If you do not hear a rush of air, repeat the priming procedure.

Page 75

MAINTENANCE

Oil Level

Transmission Oil

Maintain the oil level at the bottom of the fill plug hole threads. Use the recommended oil.

See page 120 for the part numbers of Polaris products.

Transmission Oil Recommendations

Lubricant Oil Change

Premium AGL Synthetic

Gearcase Lubricant

Capacity

948 ml 30 N-m 30 N-m

Transmission Oil Level

1. Position the vehicle on a level

surface.

2. Place the transmission in PARK.

3. Remove the fill plug.

4. Check the oil level. Add

the recommended oil as needed. Do not overfill.

5. Reinstall the fill plug.

Torque to specification.

Fill Plug

To r q u e

Drain Plug

To r q u e

Page 76

Transmission Oil

Transmission Oil Change

1. Position the vehicle on a level

surface.

2. Place the transmission in PARK.

3. Remove the fill

plug.

4. Remove the drain

plug.

5. Drain the oil into a

drain pan.

6. Clean the drain

plug.

7. Reinstall the drain

plug. Torque to specification. See page 72.

8. Add the recommended oil. See

page 72.

9. Reinstall the fill plug. Torque to

specification. See page 72.

10. Check for leaks.

11. Discard used oil properly.

MAINTENANCE

Page 77

MAINTENANCE

Drain Plug

Fill Plug

Fill Level

Front Gearcase (Demand Drive) Fluid

Fluid Recommendations

Gearcase Lubricant Capacity Fill Plug

Demand Drive

Unit

Demand Drive Plus Fluid 265 ml 11-14 N-m 15 N-m

To r q u e

Use the recommended fluid. Use of other fluids may result in improper operation of components. See page 120 for the part numbers of Polaris products.

Maintain the fluid level at the bottom of the fill hole threads.

Fluid Level

1. Position the vehicle on a level

surface.

2. Place the transmission in PARK.

3. Remove the fill plug.

4. Add the recommended demand drive fluid as needed.

5. Reinstall the fill plug. Torque to specification.

Drain Plug

To r q u e

Page 78

MAINTENANCE

Front Gearcase (Demand Drive) Fluid

Fluid Change

1. Position the vehicle on a level

surface.

2. Place the transmission in PARK.

3. Remove the fill plug.

4. Remove the drain plug.

Drain the fluid into a drain pan.

5. Clean the drain plug.

6. Reinstall the drain plug. Torque

to specification. See page 74.

7. Add the recommended fluid.

8. Reinstall the fill plug. Torque to

specification.

9. Check for leaks.

10. Discard used oil properly.

Page 79

MAINTENANCE

Cooling System

Any time the cooling system has been drained for maintenance or repair, replace the coolant with a fresh mixture of antifreeze and water. Drain the cooling system every two years. Add fresh coolant.

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 premixed and ready to use. Do not dilute with water. See page 120 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

Some coolant level drop on new machines is normal, as the system is purging itself of trapped air. Add coolant as needed.

Check the coolant level in the radiator any time the recovery bottle has run dry. Add coolant as needed.

1. Check the coolant level when the

fluid is cool.

2. Remove the left side panel. See page

85.

3. Maintain the coolant level between

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

4. View the coolant level.

5. Add coolant as needed.

6. Reinstall the side panel.

Page 80

MAINTENANCE

Cooling System

Radiator Coolant

Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot.

1. Open the front box cover.

2. Open the access door.

3. Remove the radiator pressure

cap.

4. If coolant is not visible,

slowly add coolant through the radiator filler neck.

5. Reinstall the pressure cap.

6. Secure the access door and

box cover.

NOTICE: Use of a non-standard

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

Page 81

MAINTENANCE

Brake Fluid

Check brake fluid levels for both brake systems before each ride. Always maintain brake fluid at the recommended level. Do not overfill.

The brakes should feel firm when they're applied. Spongy or weak brakes may indicate a fluid leak or low fluid level. A low fluid level may also mean that brake pads are worn and need to be replaced. Do not operate the vehicle with spongy or weak brakes. See your dealer for service.

Operating the vehicle with a spongy brake can result in loss of braking, which could cause an accident. Never operate the vehicle with spongy-feeling brakes.

If the fluid level is low add DOT 4 brake fluid only. See page 120 for the part numbers of Polaris products.

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

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.

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

Page 82

MAINTENANCE

Master

Cylinder

Indicator

Window

Full

Low

Brake Fluid

Hand Brake

The master cylinder is located on the left handlebar. Maintain the fluid level 6 mm below the top edge of the master cylinder. Do not overfill.

1. Position the vehicle on a

level surface. Make sure the handlebars are straight.

2. View the fluid level

through the indicator window (eye) 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.

3. Add the recommended fluid as needed. Do not overfill.

Page 83

MAINTENANCE

Minimum

Maximum

Brake Fluid

Reservoir

Brake Fluid

Foot Brake

The foot brake fluid reservoir is located under the front box. The brake fluid reservoir cap is black.

1. Position the vehicle on a level

surface.

2. Open the front box cover.

3. Open the access door.

4. View the fluid level in the

reservoir.

5. Remove the cap and add the

recommended fluid as needed.

NOTICE: Always use the

6. Maintain the fluid level

recommended brake fluid.

between the minimum and maximum marks. Do not overfill.

Page 84

MAINTENANCE

1 mm

Brakes

The front and rear brakes are hydraulic disc brakes, activated by applying the foot brake. The handlebar brake is also hydraulic. Both brake systems are self-adjusting.

Brake Inspections

Perform the following checks to keep the brake systems 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 78.

2. Check the brake systems regularly for

fluid leaks.

3. Check the brakes for excessive travel or

spongy feel.

4. Check the friction pads for wear, damage

and looseness. Replace the pads when the friction material is worn to 1 mm.

5. Check the security and surface condition

of the disc.

Page 85

MAINTENANCE

String

Stand

Toe Alignment

Do not attempt to adjust alignment. All steering adjustments should be performed by an authorized Polaris dealer.

Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 3-6 mm toe out.

1. Position the vehicle on a level surface.

2. Place the handlebars in a

straight-ahead position.

3. Tie a length of string

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

Tip: If available, you may use a

long straight-edge 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 2-3 mm more than the front measurement on each side of the vehicle to obtain the recommended 3-6 mm toe out alignment.

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

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

vice.

Page 86

MAINTENANCE

14-17 N-m

Handlebar Adjustment

The handlebars can be adjusted for rider preference.

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

1. Remove the upper headlight pod.

2. Loosen the four handlebar bolts.

3. Adjust the handlebar to the desired height.

4. Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right.

5. Torque the front two bolts to 14-17 N-m, then torque the rear two bolts. A gap of up to 3 mm will remain at the rear of the clamp blocks.

Page 87

MAINTENANCE

Adjuster

Steering Assembly

Check the steering assembly of the vehicle periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle.

Rear Spring

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

Page 88

Side Panel Removal

Screws

Rivets

1. Remove the seat.

2. Grasp the rear of the side panel near the rear cab.

3. With a firm motion, pull the panel outward to disengage the side panel from the grommet.

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

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

MAINTENANCE

Footwell Removal

1. Remove the six screws on

the bottom of the footwell.

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

3. Remove the footwell.

Page 89

MAINTENANCE

Boot

Lock Nut

Adjuster

1.6-3.2 mm

Throttle Cable Freeplay

Adjust throttle cable freeplay at the handlebar.

1. Locate the throttle cable adjuster at the handlebar.

2. Squeeze the end of the rub-

ber boot and slide it far enough to expose the end of the inline cable adjuster.

3. Loosen the adjuster lock nut.

4. Rotate the boot to turn the

adjuster until 1.6-3.2 mm of freeplay is achieved at the thumb lever. Move the throttle lever back and forth while adjusting.

5. Tighten the lock nut.

6. Squeeze the end of the

rubber boot and slide it over the cable adjuster to its original position.

Tip: Engine RPM should not increase when steering is turned full left or right.

Readjust cable freeplay if this occurs.

Page 90

MAINTENANCE

WARNING

3 mm

Tires

Operating your vehicle with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident.

• Maintain proper tire pressure as described on the label on your vehicle and in the specifications section of the owner's manual.

• Use only original equipment size and type when replacing tires.

• Make sure the wheels are installed properly.

• Replace tires when the tread depth measures 3 mm or less.

Refer to the specifications section beginning on page 118 for recommended tire type, size and pressure.

Front Wheel Hub Tightening

Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized Polaris dealer.

Tire Tread Depth

Always replace tires when tread depth is worn to 3 mm or less.

Page 91

MAINTENANCE

Cast Aluminum Steel

122 Nm

37 Nm

Tires

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 122 Nm

2-Piece Flange Nut 37 Nm

Page 92

MAINTENANCE

Tires

Always use original equipment size and type when replacing tires. Install wheels properly.

Wheel Removal/Installation

1. Position the vehicle on a level

surface.

2. Place the transmission in PARK.

3. Loosen the wheel nuts

slightly.

4. Place a suitable stand under

the footrest frame to raise the wheel slightly off the ground.

5. Remove the wheel nuts.

6. Remove the wheel.

7. Place the wheel on the hub.

8. Install the wheel nuts finger

tight.

9. Lower the vehicle to the

ground.

10. Torque the wheel nuts to

specification. See torque chart on page 88.

Page 93

MAINTENANCE

Main Filter

Pre-Filter

Air Filter

Always clean and replace the air and breather filters at the intervals outlined in the Periodic Maintenance Chart beginning on page 61.

1. Position the vehicle on a level surface.

2. Place the transmission in PARK.

3. Remove the seat.

4. Release the air box

cover clips.

5. Remove the air

box cover.

6. Loosen the hose

clamp.

7. Remove the filter.

8. Remove the pre-filter

from the filter.

9. Wash the pre-filter in soapy water. Rinse and air dry.

10. Replace the filter if needed.

11. Reverse the steps to reinstall all components.

Page 94

MAINTENANCE

Breather Filter

Breather Filter/Hose

The breather filter is on the hose between the engine and air box.

1. Remove the left side panel. See page 85.

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.

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

Operation of your vehicle without a breather filter can cause engine damage.

Page 95

MAINTENANCE

7.6 m

5 cm

Screw

Lights

High Beam Adjustment

The headlight beam can be adjusted slightly upward or downward.

1. Position the vehicle on a level surface. The headlight should be approximately 7.6 m from a wall.

2. Place the transmission in PARK.

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

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

Tip: Include rider weight on the seat when measuring.

4. Start the engine.Turn the head-

light switch to high beam.

5. Observe the headlight aim on the

wall. The most intense part of the headlight beam should be 5 cm below the mark on the wall.

6. Tighten or loosen the lower

headlight screws to adjust the beam upward or downward or to the left or right.

Page 96

MAINTENANCE

Position Light

Collar

Socket

Headlamp

Lights

Poor lighting can result in loss of control or an accident. Lights become dirty during normal operation. Wash the headlights and taillights frequently.

Hot components can cause serious burns to skin. Do not service the headlamps until they've cooled.

Headlight/Position Light Lamp Replacement

When servicing a halogen lamp, do not 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. Hold the plastic part of the lamp.

1. Place the transmission in PARK.

2. Open the front rack cover.

3. Remove the plug at the back of the headlight.

4. Pull the harness plug to disconnect it from the back of the headlight.

5. Position light: Rotate the socket to remove it. Go to step 6. Headlamp: Reach under the bumper and remove the rubber cover from the back of the headlight. Turn the collar counterclockwise and carefully remove the collar and socket.

6. Remove the lamp. Apply dielectric grease to the socket and install a new lamp.

7. Reverse all steps to reassemble the headlight.

Page 97

MAINTENANCE

Screw

Lamp

Lights

Taillight Lamp Replacement

1. Place the transmission in PAR K.

2. Rotate the taillight socket

counterclockwise to remove it.

3. Remove the lamp.

4. Apply dielectric grease to the

socket.

5. Install the new lamp. Test the lamp for proper operation.

6. Reinstall all components in reverse order.

Front Turn Signal Lamp Replacement

1. Place the transmission in PAR K.

2. Remove the lens attachment

screw.

3. Rotate the lamp to remove it.

4. Install the new lamp.

5. Reinstall the lens.

Rear Turn Signal Lamp Replacement

1. Place the transmission in PARK.

2. Rotate the turn signal socket

counterclockwise to remove it.

3. Remove the lamp.

4. Apply dielectric grease to the

socket.

5. Install the new lamp. Test the lamp for proper operation.

6. Reinstall all components in reverse order.

Page 98

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.

Tip: Spare fuses are provided in a compart-

ment 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. Install a new fuse with the same amperage.

4. Secure the access door.

5. Secure the box cover.

MAINTENANCE

Page 99

MAINTENANCE

Spark Plugs

Spark Plug Recommendations

Refer to the specifications section beginning on page 118 for the recommended spark plug type and gap for your vehicle. Torque spark plugs to specification.

Plug Condition Torque Specification

New Spark Plug 12-15 N-m

Previously Installed Spark Plug 23-27 N-m

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.

Normal Spark Plug

The normal insulator tip is tan or 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 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.

Page 100

Spark Plugs

Spark Plug Removal

1. Remove the left side panel.

See page 85.

2. Remove the spark plug cap.

3. Use the spark plug wrench to remove the spark plug. Turn the plug counterclockwise to remove it.

4. Inspect the electrodes for wear and carbon buildup. Replace worn or fouled plugs. Verify that the gap is at specification before installation.

MAINTENANCE

5. Reinstall the spark plug. Torque to specification. See page 96.

6. Reinstall the spark plug cap.