Polaris Sportsman Forest 800 User Manual

PMS 419

Sportsman Forest 800

Owner's Manual

for Maintenance and Safety

Read this manual carefully. It contains important safety information.

Operation is prohibited for those under 16 years of age.

This is an adult vehicle only.

WELCOME

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

• 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
needs during (and after) the warranty period.

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

®

utility vehicles

®

®

(MSD) technician. Please see your dealer for all of your service

1

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

Copyright 2011 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.

The original instructions for this vehicle are in English. Other languages are provided as
translations of the original instructions.

Printed in U.S.A.
2012 SPORTSMAN FOREST 800 Owner’s Manual
P/N 9923428

2

TABLE OF CONTENTS

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

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

Features and Controls . . . . . . . . . . . . . . . . . . . 26

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Winch Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Emission Control Systems . . . . . . . . . . . . . . . 69

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 118

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 122

POLARIS Products. . . . . . . . . . . . . . . . . . . . . 124

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

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.

• 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.

5

INTRODUCTION

####

VIN

(front or rear frame)

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

Never operate this vehicle without proper instruction. Take a training
course.

For more information about safety, contact an authorized POLARIS
dealer or visit the POLARIS web site at www.polarisindustries.com.

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 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.

9

SAFETY

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. 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.

Never operate this vehicle without proper
instruction. Take a training course. Beginners
should receive training from a certified instructor.

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.

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 ATVs,
he/she may not have the skills, abilities, or
judgment needed to operate an ATV safely and
could be susceptible to accident or injury.

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.

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 ATV on pavement. ATV
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
ATV. 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 53.

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 owner's
manual. NOTE: A special technique is
required when braking while traveling down­hill. See page 55.

• 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 54.

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 56.

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 56.

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 56.

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 59.

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.

18

SAFETY

Safety Warnings

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 58.

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.

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

57):

• 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.

19

SAFETY

Safety Warnings

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 dis­tance for braking.

• NEVER exceed 50 MPH (80 km/h) when rear cargo loads are above 75 lbs.
(34 kg) and/or front cargo loads are above 37 lbs. (17 kg).

• Always follow the instructions in the owner's manual for carrying cargo or pull­ing a trailer.

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 unless you have indepen­dently verified that the ice is sufficiently thick to support the weight and moving
force of the ATV, you and your cargo, together with any other vehicles in your
party. Variances in snow depth and/or water currents may result in uneven ice
thickness. Always check with local authorities and residents to confirm ice condi­tions and thickness over your entire route. ATV operators assume all risk associ­ated with ice conditions on frozen bodies 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 ATV 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.

20

SAFETY

Safety Warnings

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 operate 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.

21

SAFETY

Safety Labels and Locations

Warning labels have 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

WARNING

Improper ATV use can result in SEVERE INJURY or DEATH

ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR
NEVER USE ON PUBLIC ROADS
NEVER CARRY PASSENGERS
NEVER USE WITH DRUGS OR ALCOHOL
NEVER operate:

• without proper training or instruction

• at speeds too fast for your skills or the conditions

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

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

ALWAYS:

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

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

LOCATE AND READ OWNER’S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.

22

Safety Labels and Locations



Tire Pressure/Load

Warning

General Warning



Discretionary

Warning



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: 515 lbs. (234 kg)

SAFETY

Discretionary Warning

WARNING

• Never operate this ATV on HILLS

steeper than 25 degrees 25. To pre­vent 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.

23

SAFETY





“No Passenger”

Warning

Age 16

Warning



Rack

Warning



Rack

Warning



Clutch Cover

Warning

Hitch

Capacity

Safety Labels and Locations

“No Passenger” Warning

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

DEATH.

Age 16 Warning

WARNING
Operating this ATV if you are under the age of 16 increases your chance of

severe injury or death.
NEVER operate this ATV if you are under age 16.

24

SAFETY

Safety Labels 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

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 100 lbs. (45 kg) Rear 200 lbs. (91 kg)

Reverse Override Warning/4X4 Caution

WARNING
Improper use of the override button can lead to loss of control resulting in severe

injury or death. Do not activate override while throttle is engaged. Always apply
throttle gradually, while in reverse.

25

FEATURES AND CONTROLS

Mode/Reverse

Override

Switch

Main Key Switch

Engine

Stop Switch

Headlight

Switch

AWD

Switch

OUT

IN

Winch 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 AWD in reverse, if the
AWD 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.

Winch Switch

See page 63 for winch information.

26

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 49 for starting pro­cedures.

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.

27

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.

28

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.

29

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.

30

FEATURES AND CONTROLS

Parking Brake

Locking the Parking Brake

1. Place the transmission in

PAR K.

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.

31

FEATURES AND CONTROLS

WARNING

Auxiliary Foot Brake

Foot Brake Fluid

Reservoir

Auxiliary Foot Brake

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

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

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
under the seat on the left side of
the vehicle. Maintain the fluid
level between the maximum and
minimum marks.

32

FEATURES AND CONTROLS

Gear

Selector

Fuel

Tank

Cap

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 the engine speed above idle or while the vehicle is

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

Belt Life

To extend belt life, use low forward gear when pulling a heavy load at
less than seven miles per hour for extended periods and when operating
uphill at a slow speed.

Fuel Tank Cap

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 fuel with etha-

nol content greater than 10 percent,
such as E-85 fuel.

moving could cause transmission damage.

33

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 two­wheel drive at all times.
When the switch is on AWD,
the ATV is in all wheel drive
and the AWD indicator light
in the instrument cluster will
be on.

When in AWD, the 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 AWD.

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

is on. See page 26.

Engaging AWD

The AWD switch may be turned on or off while the vehicle is moving.
Initially, the vehicle's electronic system will not enable AWD until the
engine RPM is below 3100. Once enabled, 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.

NOTICE: Switching to AWD while the rear wheels are spinning may cause

severe drive shaft and gearcase damage. Always switch to AWD
while the rear wheels have traction or are at rest.

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 26
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 on AWD.

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

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. It also
appears if an EFI-related fault occurs. 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 26. 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.

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.

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 all­wheel-drive coil. This screen is for informational purposes only. Please
see your dealer for all major repairs.

Gear Circuit Diagnostic Screen

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

Programmable service interval

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

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Downloading Codes

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

See page 43 for Blink Codes and Failure Descriptions. Use the follow­ing procedure to download blink codes (failure codes) from the EFI
module.

1. Place the transmission in PARK.

2. Stop the engine.

3. Turn the key switch to the ON position.

4. Turn the key switch off and on three times in less than five seconds,

then leave the switch on. Any blink code numbers stored in the EFI
module will display, one at a time, on the screen. The number “61”
and the word “END” displays after all codes have been transmitted.

41

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Downloading Codes

Code Definitions

Open Load:

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

Short-to-Ground:

control unit and the item listed in the chart.

Shorted Load:

shorted together, or the item has shorted internally.

Short-to-Battery:

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

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

The wire is shorted to ground between the electronic

The wires leading to the item listed in the chart are

The wire leading from the item listed in the chart to

42

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Downloading Codes

Blink
Code

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

Failure Description

43

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.

44

OPERATION

Break-In Period

Engine and Drivetrain Break-in

1. Fill the fuel tank with gasoline. See page 33. Always exercise

extreme caution whenever handling gasoline.

2. Check the engine oil level on the dipstick. See page 76. Add oil if

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

3. Drive slowly at first. Select an open area that allows room to 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 46.

6. Pull only light loads.

7. Change both the oil and the filter at 20 hours or one month, which-

ever comes first.

PVT Break-in (Clutches/Belt)

A proper break-in of the clutches and drive belt will ensure a longer life
and better performance. Break in the clutches and belt by operating at
slower speeds during the break-in period as recommended. Pull only
light loads. Avoid aggressive acceleration and high speed operation dur­ing the break-in period.

If a belt fails, always clean away all debris when replacing the belt.

45

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 29

Brake fluid Ensure proper level 30

Auxiliary brake Ensure proper operation 32

Front suspension Inspect, lubricate if necessary 75

Rear suspension Inspect, lubricate if necessary 75

Steering Ensure free operation -

Tires Inspect condition and pressure 89

Wheels/fasteners Inspect, ensure fastener tightness 89

Frame nuts, bolts, fasteners Inspect, ensure tightness -

Fuel and oil Ensure proper levels 33

Coolant level (if applicable) Ensure proper level 82

Coolant hoses (if applicable) Inspect for leaks -

Throttle Ensure proper operation 28

Indicator lights/switches Ensure operation 26

Engine stop switch Ensure proper operation 27

Air filter, pre-filter Inspect, clean 91

Air box sediment tube Drain deposits whenever visible -

Headlamp Check operation, apply POLARIS

Brake light/tail lamp Check operation, apply POLARIS

Riding gear Wear approved helmet, goggles, and

Winch Inspect cable and switch. 64-65

dielectric grease when lamp is
replaced

dielectric grease when lamp is
replaced

protective clothing

84

90

76

83

87

27
93

97

8

46

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 unless you have

independently verified that the ice is sufficiently thick to support the
weight and moving force of the ATV, you and your cargo, together
with any other vehicles in your party.

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.

47

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. Tread 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.

48

OPERATION

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

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

6. 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.

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

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

NOTICE: Operating the vehicle immediately after starting could cause engine

Cold Weather Operation

If the ATV is used year-round, check the oil level frequently. A rising oil
level could indicate the accumulation of contaminates such as water or
excess fuel in the bottom of the crankcase. Water in the bottom of the
crankcase can lead to engine damage and must be drained. Water accu­mulation increases as outside temperature decreases.

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

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

49

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.

50

OPERATION

Turning the Vehicle

Your ATV is equipped with
a solid rear axle, which
drives both rear wheels
equally at all times. This
means that the wheel on the
outside of the turn must
travel a greater distance
than the inside wheel when
turning and the inside tire
must slip traction slightly.

To turn, steer in the direc­tion of the turn, leaning
your upper body to the
inside of the turn while
supporting your weight on
the outer footrest. This
technique alters the balance
of traction between the rear
wheels, allowing the turn to be made smoothly. The same leaning tech­nique should be used for turning in reverse.

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.

51

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.

52

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. Drive straight uphill.

2. Avoid steep hills (25 maximum).

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

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

5. Keep both feet on the footrests.

6. Shift body weight uphill.

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

throttle suddenly could cause the ATV to flip over backwards.

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

include quick dismounting of the vehicle.

53

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

possible, or dismount on the uphill side immediately!

54

OPERATION

Driving Downhill

When driving downhill, follow these precautions:

1. Avoid steep hills (25 maximum).

2. Shift body weight uphill.

3. Drive straight downhill.

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

loss of control.

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

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

55

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

3. Dismount on the uphill side of the vehicle, or on the left if the vehi-

cle is pointing straight uphill.

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

5. While holding the service brake, release the parking brake lock and

slowly allow the vehicle to roll around to your right until it's point­ing across the hill or slightly downward.

6. Lock the parking brake and remount the vehicle from the uphill

side, keeping body weight uphill.

7. Restart the engine with the transmission still in forward.

8. Release the parking brake and proceed slowly, controlling speed

with the service brake, until the vehicle is on more level ground.

56

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 70. The following areas need
special attention: engine oil, transmission oil, demand drive fluid, rear
gearcase oil (if equipped), 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 100,
then see your dealer for service at the first opportunity.

.

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

57

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.

58

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.

59

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 RECOMMENDED SPEEDS.
NEVER exceed 50 MPH (80 km/h) when rear cargo loads are above 75 lbs. (34

kg) and/or front cargo loads are above 37 lbs. (17 kg).
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.

60

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.

NEVER exceed 50 MPH (80
km/h) when rear cargo loads are
above 75 lbs. (34 kg) and/or
front cargo loads are above 37
lbs. (17 kg).

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, cargo and weight on hitch) must

not exceed the maximum weight capacity of the vehicle.

• Unbraked Trailer Towing Capacity is 1914 lbs. (868 kg) based on EU

Directive 76/432/EC.

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 install a hitch longer
than 4" (10 cm). Never install
automotive accessories on your
POLARIS ATV. Always install
POLARIS-approved (or equivalent)
accessories designed for ATV use.

61

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.

62

WINCH GUIDE

WARNING

DANGER

Danger Zone

The responsibility for safe operation of the winch ultimately rests with
you, the operator. Read and understand all safety precautions and oper­ating instructions before operating the winch. Careless operation can
result in serious injury. DO NOT use the winch to lift or move people.

Winch Safety Precautions

1. Be alert. Do not operate the winch under the influence of drugs,

alcohol or medication.

2. Practice using the winch so you are prepared to use it in an emer-

gency situation.

Never connect DC powered winches to AC current. Motor damage or fatal
shock may occur.

Stand clear of the cable and load during winching. Keep helpers and spectators
at a safe distance. If a cable pulls loose or breaks under the load, it can lash
back with dangerous force.

3. Beware of the danger zone.

The danger zone is the area
of the rotating wire cable
drum, the fairlead (if fitted),
the cable, the hook and the
motor. Before placing hands
in or near the danger zone,
first relieve tension on load,
then disconnect the control
switch.

4. If you are within four feet of the winch, do not hold the cable and

the remote (if equipped) at the same time.

63

WINCH GUIDE

A

B

C

Winch Cable Care

1. The life of a cable is directly related to the care it receives. The wire

cable on a new winch (and any replacement cables) must be re­spooled under a minimum of a 100-lb. (45.4-kg) load before use.
Failure to do this will result in cable damage.

2. Inspect all cable before use. Mashed, pinched, frayed or kinked

areas severely reduce the load-carrying capability. Replace dam­aged cable promptly.

3. Prevent kinks before they occur.

A. This is a start of a kink. Straighten

the cable before using it.

B. The cable was pulled and the loop

has tightened to a kink. The cable
is now permanently damaged and
should not be used.

C. The result of kinking is that each

strand pulls a different amount of
load, causing the strands under the
greatest tension to break. This
reduces the load capacity of the
entire cable.

4. Before re-spooling, remove all load from the cable. Hold the han-

dlebar switch lead in one hand and the cable in the other. Move
away from the vehicle as far as the switch will allow. Activate the
switch, walk in several feet of cable, then release the switch. Repeat
this process until the re-spooling is complete.

CAUTION! To avoid injury, always release the switch before your hand comes
within four feet of the fairlead (the physical opening through which the cable
passes).

5. Be sure the cable is distributed evenly and tightly on the drum. A

loosely wound drum may allow the cable to work its way down into
the layers of cable on the drum and become wedged.

6. Do not grease or oil the cable. Doing so causes dirt contamination

that will reduce the life of the cable.

64

WINCH GUIDE

DANGER

WARNING

DANGER

Winch Preparation and Inspection

Wear heavy leather gloves whenever
handling cable. Do not allow the cable
to slip through your hands, even with
gloves on. When handling the hook,
always use a handsaver. Never place
fingers into the hook. Placing fingers in
the hook could result in injury.

Inspect the switch and wiring for cracks, pinched spots, frayed wire or loose
connections. A damaged, shortened lead could cause the winch to operate as
soon as it is plugged in.

Never touch the cable or hook while they are in tension
or under load. Even at rest, the winch may have the
cable in tension. Never guide a cable under tension onto
the drum with your hand.

1. Winch with at least five wraps of cable around

the winch drum. With fewer wraps, the cable
could pull loose from the drum under load.

65

WINCH GUIDE

WARNING

WARNING

Winch Rigging

Take your time when rigging and use extra caution. Improper rigging can result
in injury in addition to damage to the vehicle and equipment. Never handle the
cable or rigging while another person is at the control switch.

1. Use a nylon sling to

attach the cable to
an anchor point.

CAUTION! Do not attach
the hook back onto the
cable. Doing so can cause
the cable to break.

Always use a handsaver. Do not hold the hook
with your hand. This is important not only
when reeling cable in but also when removing
cable from the winch under power.

2. Run the winch intermittently to take

up cable slack. When using a pulley
block, be sure the cable is running
properly in all pulleys before apply­ing a load.

CAUTION! Never engage or disengage the clutch if the winch is under load,
the cable is in tension or the drum is rotating.

66

WINCH GUIDE

Winch Operation

NOTICE: This winch is designed for intermittent use. Prolonged use may result

1. Use common sense.

2. Take your time.

3. Think through the situation.

4. Pay attention to what is going on when you are winching.

5. DO NOT overheat the winch motor. During extended winching,

6. Extended winching will discharge your battery. If the low battery

7. DO NOT overload or stall the winch. If the load is greater than the

8. Avoid continuous side pulls.

9. Never tow the vehicle by the winch cable.

10. Never use the winch cable as a tie-down.

11. Use an anchor point that is stronger than what you are pulling.

12. DO NOT hook the cable back onto itself. This will damage the

in damage due to overheating.

stop and feel the winch motor. The motor should be cool enough to
touch. If not, allow the motor to cool before continuing.

warning light comes on, stop winching. Make sure the transmission
is in neutral or park, then rev the motor for a few minutes until the
warning light goes out. Recharge the battery as soon as possible.

winch is capable of pulling, use a snatch block.

cable.

67

WINCH GUIDE

Winch Operation

13. Use as much cable as possible when pulling. Additional wraps of

cable on the spool will significantly reduce the pulling power of
your winch. If the winch is still not capable of pulling the load, use
a snatch block.

14. Never pull with less than five wraps of cable on the spool.

15. Inspect the condition of the cable prior to pulling. If the cable is

frayed or damaged, replace it as soon as possible.

16. DO NOT submerge the winch in water.

68

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 Arrester

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

Exhaust Emission Control System

Exhaust emissions are controlled by engine design. An electronic fuel
injection (EFI) system controls fuel delivery. The engine and EFI com­ponents are set at the factory for optimal performance and are not
adjustable.

Electromagnetic Interference

This vehicle complies with the EMC requirements of European direc­tives 97/24/EC and 2004/108/EC.

Non-ionizing Radiation: This vehicle emits some electromagnetic
energy. People with active or non-active implantable medical devices
(such as heart monitoring or controlling devices) should review the lim­itations of their device and the applicable electromagnetic standards and
directives that apply to this vehicle.

European Vibration and Noise

The driver-perceived noise and hand/arm and whole body vibration lev­els of this machinery is measured per prEN 15997.

The operating conditions of the machinery during testing:
The vehicles were in like-new condition. The environment was con-

trolled as indicated by the test procedure(s).
The uncertainty of vibration exposure measurement is dependent on

many factors, including:

• Instrument and calibration uncertainty

• Variations in the machine such as wear of components

• Variation of machine operators such as experience or physique

• Ability of the worker to reproduce typical work during measurements

• Environmental factors such as ambient noise or temperature

69

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.

70

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

 Perform these operations more often for vehicles subjected to severe

use.

 Have an authorized POLARIS dealer perform these services.

71

MAINTENANCE

Periodic Maintenance Chart

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 travel - Pre-Ride -

Brake system - Pre-Ride -

Wheels/fasteners - Pre-Ride -

Frame fasteners - Pre-Ride -

 Engine oil level - Pre-Ride -

Winch - Pre-Ride - See pages 64-65.

 Air filter, pre-filter - Daily - Inspect; clean often; replace

 Air box sediment

tube

Coolant
(if applicable)

Headlamp/taillight - Daily - Check operation; apply

 Air filter,

main element

Recoil housing
(if applicable)

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

(whichever comes first)

Hours Calendar Miles

- Daily - Drain deposits when visible

- Daily - Check level daily, change

- Weekly - Inspect; replace as needed

- Weekly - Drain water as needed,

(Km)

ed. See Pre-Ride Checklist
on page 46.

as needed

coolant every 2 years

dielectric grease if replacing

check often if operating in wet
conditions

Remarks

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

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

(if equipped)

 Transmission oil 25 H Monthly 250 (400) Inspect level; change yearly
 Engine breather

filter (if equipped)

 Perform these procedures more often for vehicles subjected to severe use.
 Have an authorized POLARIS dealer perform these services.

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

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

72

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

 General

lubrication

 Throttle Cable/

ETC Switch

Throttle Body
Intake Duct

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

Cooling system
(if applicable)

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

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

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

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

 Radiator 100 H 12 M 1000 (1600) Inspect; clean external

 Cooling hoses

(if applicable)

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

Exhaust muffler/
pipe

 Spark plug 100 H 12 M 1000 (1600) Inspect; replace as needed
 Wiring 100 H 12 M 1000 (1600) Inspect for wear, routing,

(whichever comes first)

Hours Calendar Miles

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

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

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

50 H 6 M 1000 (1600) Inspect coolant strength

100 H 12 M 1000 (1600) Inspect for leaks

100 H 12 M 1000 (1600) Inspect

(Km)

cables, etc.

replace if necessary

ing/air leaks

needed

seasonally; pressure test
system yearly

at one month

lines, filter, pump; replace
lines every two years

surfaces

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

Remarks

73

MAINTENANCE

Periodic Maintenance Chart

Item Maintenance Interval

 Clutches (drive

and driven)

 Front wheel

bearings

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

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

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

 Toe adjustment - Inspect periodically; adjust

Headlight aim - Adjust as needed

 Perform these procedures more often for vehicles subjected to severe use.
 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

(Km)

parts

Replace every 2 years, more
often under extreme
conditions.

when parts are replaced

Remarks

74

MAINTENANCE

Front Prop Shaft Yoke

Lubrication Guide

Check and lubricate all components at the intervals outlined in the Peri­odic Maintenance Chart beginning on page 70. 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

Engine Oil PS-4 PLUS Performance

Brake Fluid DOT 4 Only --- See page 30.

Transmission Oil AGL PLUS Transmission

Demand Drive
Fluid (Front
Gearcase)

Front Prop Shaft
Yoke

Synthetic 2W-50

Fluid

Demand Drive Plus Fluid 9 oz. (265 ml) See page 81.

POLARIS Premium U­Joint Lube

Fluid Change

2 qt. (1.9 l) See page 76.

32 oz. (946 ml) See page 79.

--- Grease fittings (3

Inspection
Procedure

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

75

MAINTENANCE

Dipstick

Safe

Add Oil

{

Safe

Range

Check Level

on Top Side

Engine Oil

Oil Recommendations

POLARIS recommends the use of POLARIS PS-4 PLUS Performance
Synthetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may
need to be changed more frequently if POLARIS oil is not used. Always
use 2W-50 oil. Follow the manufacturer's recommendations for ambient
temperature operation. See page 124 for the part numbers of POLARIS
products.

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

Oil Level

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

1. Position the vehicle on a level

2. Lift the lever lock to remove the

3. Reinstall the dipstick completely,

4. Remove the dipstick and check

Tip: Due to the dipstick entry angle into

5. After reinstalling the dipstick,

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

surface.

dipstick. Wipe it dry with a clean
cloth.

but do not lock it. The dipstick
must be inserted completely to
keep the angle and depth of the
stick consistent.

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

the crankcase, the oil level will read
higher on the bottom side of the dip­stick. Always read the level on the
upper surface of the dipstick.

seat the lever lock.

76

MAINTENANCE

Drain Plug Location

to front

Engine Oil

Oil and Filter Change

Always change the oil and filter at the intervals outlined in the Periodic
Maintenance Chart beginning on page 70. Always change the oil filter
whenever changing oil.

1. Position the vehicle on a level surface.

2. Start the engine. Allow it to warm up at idle for two to three min-

utes.

3. Stop the engine.

4. Clean the area around

the drain plug.

5. Place a drain pan

under the crankcase.

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 20 ft. lbs. (27 Nm).

9. Place shop towels beneath the oil

filter. Using an oil filter wrench
(available from your POLARIS
dealer), turn the filter counter­clockwise to remove it.

10. Using a clean dry cloth, clean the

filter sealing surface on the
crankcase.

77

MAINTENANCE

Engine Oil

Oil and Filter Change

11. 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.

12. 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.

13. Remove the dipstick.

14. Add two quarts (1.9 l) of recommended oil.

15. Place the transmission in PARK.

16. Lock the parking brake.

17. Start the engine. Allow it to idle for one to two minutes.

18. Stop the engine.

19. Check for leaks.

20. Check the oil level. Add oil as needed to bring the level to the upper

mark on the dipstick.

21. Dispose of used filter and oil properly.

78

MAINTENANCE

Drain Plug

Fill Plug

Transmission Oil

Always check and change the transmission oil at the intervals outlined
in the Periodic Maintenance Chart beginning on page 70. Maintain the
oil level at the bottom of the fill plug hole threads. See page 124 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.

Transmission Oil Recommendations

Lubricant Capacity Fill Plug

AGL PLUS Transmission Fluid 32 oz.

(946 ml)

Tor que

10-14 ft. lbs.

(14-19 Nm)

Drain Plug

Torque

10-14 ft. lbs.

(14-19 Nm)

79

MAINTENANCE

Fill Level

Fill Plug

Transmission Oil

Oil Check

1. Position the vehicle on a level

surface.

2. Remove the fill plug. Check the

oil level.

3. Add the recommended fluid as

needed to bring the level to the
bottom of the fill hole threads.

4. Reinstall the fill plug. Torque to

specification.

Oil Change

1. Remove the fill plug.

2. Place a drain pan under the gearcase. Remove the drain plug. Allow

the oil to drain completely.

3. Clean and reinstall the drain plug. Torque to specification.

4. Add the proper amount of the recommended oil.

5. Reinstall the fill plug. Torque to specification.

6. Check for leaks.

7. Dispose of used oil properly.

80

MAINTENANCE

Drain Plug

Fill
Plug

Fill Level

Front Gearcase (Demand Drive) Fluid

Always check and change the demand drive fluid at the intervals out­lined in the Periodic Maintenance Chart beginning on page 70. We rec­ommend the use of Demand Drive Plus Fluid. Use of other fluids may
result in improper operation of components. See page 124 for the part
numbers of POLARIS products.

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

Demand Drive Capacity

Demand Drive 9 oz. (265 ml)

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.

Fluid Check

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

2. Add the recommended

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.

2. Place a drain pan under the demand drive unit. 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 table above for capacity.

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

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

81

MAINTENANCE

Recovery

Bottle

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 anti­freeze/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
124 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 88.

2. Maintain the coolant level

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

3. Add coolant as needed.

82

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.

2. Remove the access panel
screws. Squeeze the outer
edges of the panel inward to
remove the panel.

3. Remove the pressure cap.

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

5. 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.

6. Reinstall the access panel and secure the front box cover.

83

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 30.

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 32.

84

MAINTENANCE

String

Stand

2

1

FRONT

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 from improper toe alignment and
adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments
should be performed by an authorized POLARIS dealer.

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 of the vehicle.

6. If you discover improper alignment, see your POLARIS dealer for

service.

85

MAINTENANCE

Adjuster

Handlebar

Bolts

Camber and Caster

The camber and caster are non-adjustable.

Rear Spring

The rear shock absorber spring is adjusted
by rotating the adjuster either clockwise
or counter-clockwise to increase or
decrease spring tension. Accessory
springs are available through your
POLARIS dealer.

Handlebars

The handlebars can be adjusted for rider
preference.

WARNING! Improper adjustment of the handlebars or incorrect torquing of the
adjuster block tightening bolts can cause limited steering or loosening of the
handlebars, resulting in loss of control and serious injury or death. 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

10-12 ft. lbs. (14-17 Nm), then
torque the rear two bolts. A
gap of up to 1/8" (3 mm) will
remain at the rear of the clamp
blocks.

86

MAINTENANCE

Lock Nut

Adjuster

Boot

Throttle Body/Idle RPM

Idle RPM is preset by the manufacturer. If the engine idle speed is not
satisfactory, please see your POLARIS dealer for adjustment.

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 1/16" to 1/8"
(1.5-3 mm) of freeplay is
achieved at the thumb lever.
While adjusting freeplay, be
sure to flip the throttle lever
back and forth.

5. Tighten the lock nut.

6. Squeeze the end of the rub-

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

87

MAINTENANCE

Step 1 Step 2 Step 3

Screws

Rivets

Steering Assembly

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

Side Panel Removal

1. Remove the seat.

2. Grasp the rear of the side panel near the rear cab. With a firm
motion, pull the panel outward to disengage the side panel from the
grommet. Pull the panel downward and rearward to remove it.

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

Footwell Removal

1. Remove the four screws on

the bottom of the footwell.

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

3. Remove the footwell.

88

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 122 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.

89

MAINTENANCE

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
(Aluminum
Wheels)

2-Piece
Flange Nut
(Steel
Wheels)

90

30 ft. lbs. (41 Nm)

PLUS 1/4 TURN

27 ft. lbs. (37 Nm)

Air Filter

Main Filter

Pre-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 pre-filter
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.

MAINTENANCE

91

MAINTENANCE

Fuse Panel

Fuses

5or61520 20

Fuse Replacement

Fuse Feature Supported

5A Speedometer

15A Electronic Fuel Injection

20A (Main Fuse) Ignition, Lighting

20A Accessories, 12V Power Receptacle

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

3. Secure the front box cover.

92

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 counter-clockwise 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.

93

MAINTENANCE

25 ft.

(7.6 m)

2" (5 cm)

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 counter-clockwise.

94

Lights

Phillips

Screw

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 down-

ward.

3. Tighten the screw.

MAINTENANCE

95

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.

96

MAINTENANCE

Harness

Connector

Lamp

Lights

Lower Headlamp Replacement

1. Turn the back of the headlight
harness counter-clockwise 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 Lamp Replacement

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

2. Turn the lamp counter-clock-

wise to remove it.

3. Apply dielectric grease to the

socket and install the new
lamp.

4. Reinstall the harness connector.

5. Test the light for proper operation.

97

MAINTENANCE

Spark Plugs

Spark Plug Recommendations

Refer to the specifications section beginning on page 122 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
plugs for correct color. See page 99.

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 counter-clockwise to remove it.

cation.

98

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 fuel.

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 or incorrect throttle body adjustments.

99