Polaris Sprotsman MV7 User Manual

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WARNING

The engine exhaust from this

product contains chemicals known

to cause cancer, birth defects or

other reproductive harm.

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

Copyright 2004 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.

Printed in U.S.A.

2005 Sportsman MV7 Owner’s Manual P/N 9919959

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.

Polaris Recreational and Utility Vehicles

S Snowmobiles S All-terrain vehicles (ATVs) S Watercraft S RANGER utility vehicles S Victory motorcycles

We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever produced.

For safe and enjoyable operation of your vehicle, be sure to follow the instructions and recommendations in this owner’s manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master S ervice Dealer (MSD) Technician.

Your Polaris dealer knows your vehicle best and is interested in your total satisfaction. Be sure to return to your dealership for all of your service needs during, and after, the warranty period.

We also take great pride i n our Parts, Apparel and Accessories (PAA) products, available through our online store at www.purepolaris.com. Have your accessories and clothing delivered right to your door!

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

TABLE OF CONTENTS

WELCOME 3....................................

VEHICLE IDENTIFICATION NUMBERS 7...........

SAFETY 8......................................

CONTROLS 33..................................

FEATURES 41..................................

OPERATION 49.................................

EMISSION CONTROL SYSTEMS 68...............

MAINTENANCE AND LUBRICATION 69............

ADJUSTMENTS 109.............................

SPECIFICATIONS 112...........................

POLARIS PRODUCTS 114........................

TROUBLESHOOTING 115........................

WARRANTY 119.................................

MAINTENANCE RECORD 124....................

INDEX 127......................................

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. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys, so if both keys are lost, t he ignition switch must be replaced.

Vehicle Model Number:

Frame VIN (1):

Engine Serial Number (2):

Key Number (3):

31XX

SAFETY

Safety Decals and Locations

Warning decals have been placed on the vehicle for your protection. Read and follow the instructions of the decals carefully. If any of the decals depicted in this manual differ from the decals on your vehicle, always read and follow the instructions of the decals on the vehicle.

If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal.

WARNING

Improper ATV use can result in SEVERE INJURY or DEATH

ALWAYS USE

AN APPROVED

HELMET AND PROTECTIVE

GEAR

NEVER operate:

ALW AYS:

NEVER USE ON PUBLIC

ROADS

NEVER CARRY

PASSENGERS

WARNING

NEVER USE WITH DRUGS OR ALCOHOL

7172560

7172561

Safety Decals and Locations

WARNING

IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH.

TIRE PRESSURE IN PSI (KPa): FRONT 5 (34.5) REAR 5 (34.5)

MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight)

INCLUDING MACHINE, DRIVER AND CARGO IS 1700 LBS. (771 kg).

This vehicle i s equipped with run-flat tires. In the event of a flat tire, remove all cargo from the vehicle before riding further. Do not exceed 50 miles (80 km) at 25 MPH (40 km/h). Have the tire inspected by a dealer before further use.

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

Read Owner’s Manual for more detailed loading information

7173016

SAFETY

WARNING

ATTENTION

S Operation of this vehicle without the air

filter element will severely damage the engine.

S Clean pre-filter element often, more

frequent cleaning required in dusty conditions. Do not operate vehicle without pre-filter.

S Specific carburetor jetting and

adjustments are required depending on temperature and altitude. See your Owner’s Manual.

Factory setting:

40_ to 80_ F . at 0-3000 feet

(5_ to 27_ C. at 0-900 meters).

7172566

7172922

SAFETY

Safety Decals and Locations

WARNING

S Moving parts hazard under belt-clutch guard. To

prevent serious injury, do not operate vehicle with guard removed.

S Do not modify engine or clutch. Doing so can

cause part failure, possible imbalance, and excessive engine RPM, which can result in serious injury or death.

NO STEP

7172563

WARNING

Operating this ATV if you are under the age of 16 increases your chance of severe injury or death.

NEVER operate this ATV if you are under age 16.

7172559

S DO NOT TOW FROM RACK OR BUMPER.

Vehicle damage or tipover may r esult causing severe i njur y or death. Tow only from tow hooks or hitch.

S Max Rack Loads: Front 150 lbs. (68 kg) Rear 300 lbs. (136 kg)

7172927

Safety Decals and Locations

SAFETY

WARNING

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

7172564

MANUFACTURED BY: POLARIS IND. INC.

DATE:

VIN:

THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT INTENDEDFOR USE ON PUBLIC ROADS.

CE VÉHICUL E EST UN VÉHICUL E TOUT TERRAIN QUI NiEST PAS DESTINÉ À ÊTRE UTILIS É SUR LES CHEMINS PUBLICS.

Canadian Certification Decal

ALL WHEEL

DRIVE

SWITCH

Do not push switc h to engage AWD if the rear wheels are spinning. This may cause severe drive shaft and clutch damage. See your Owner’s Manual.

7079780

7171492

TRAILER MAX WEIGHT: 1500 LBS. (682 KG) ON LEVEL GROUND 850 LBS. (386 KG) UP TO 15° GRADE

HITCH MAX. VERTICAL WEIGHT: 150 LBS. (68KG)

7170509

SAFETY

Safe Riding Gear

Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury.

1. Helmet

Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injury.

Select an approved helmet that meets or exceeds your state’ s safety standards and bears either the Department of Transportation (DOT) label, the American National Standards Institute label (ANSI z90.1), or the Snell Memorial Foundation label.

2. Eye Protection

Do not depend on sunglasses for proper eye protection. A pair of goggles or a helmet face shield offer the best protection for your eyes. They should be kept clean and be of shatterproof design (bearing t he markings Z2.1 or VESC 8).

3. Gloves

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

4. Boots

The best footwear is a pair of strong over-the-calf boots with heels, like moto-cross boots.

5. Clothing

Always wear long sleeves and long pants to protect arms and legs. Riding pants with kneepads and a jersey with shoulder pads provide the best protection.

SAFETY

Operator Safety

WARNING

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

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

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

Age Restrictions

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

Know Your Vehicle

As the operator of the vehicle, you are responsible for your personal safety, the safety of others, and the protection of our environment. Read and understand your owner’s manual, which includes valuable information about all aspects of your vehicle, including safe operating procedures.

Safety Training

When you purchased your new ATV, your dealer offered a hands-on safety training course that covers all aspects of vehicle safety. You were also provided with printed materials that explain safe operating procedures. You should review this information on a regular basis.

If you purchased a used Polaris ATV from a party other than a Polaris dealer, you can request this free safety training from any authorized Polaris dealer.

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

We strongly advise you to strictly follow the recommended maintenance program outlined in your owner ’s manual. This preventive maintenance program is designed to ensure that all critical components on your vehicle are t horoughly inspected at specific intervals.

SAFETY

Operator Safety

The following two pages identify signal words and symbols that appear in this manual. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual.

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

WARNING

The safety alert warning indicates a potential hazard that may result in serious injury or death.

CAUTION

The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle.

CAUTION

A caution indicates a situation that may result in damage to the vehicle.

NOTE:

A note will alert you to important information or instructions.

SAFETY

Operator Safety

WARNING

Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner’s manual.

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

procedures described.

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

course. Beginners should receive training from a certified instructor.

Contact an authorized Polaris A TV dealer or call Polaris at 1-800-342-3764 to find out about the training courses nearest you.

S Never allow anyone under 16 years of age to operate this ATV. S Never permit a guest to operate the ATV unless the guest has read

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

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

walks, driveways, parking lots, and streets.

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

a dirt or gravel road.

S Never operate an ATV without wearing an approved helmet that fits

properly. Always wear eye protection (goggles or face shield), gloves, boots, a long-sleeved shirt or jacket, and long pants.

S Never consume alcohol or drugs before or while operating an ATV. S Never operate at excessive speeds. Travel at speeds appropriate for

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

S Never attempt wheelies, jumps or other stunts. S Always inspect your ATV before each use to make sure it’ s in safe

operating condition. Always follow the inspection and maintenance procedures and schedules outlined in your owner’s manual.

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

rests of the ATV during operation.

S Always travel slowly and use extra caution when operating on unfa-

miliar terrain. Be alert to changing terrain conditions.

S Never operate on excessively rough, slippery, or loose terrain. S Always follow proper turning procedures as described in this manu-

al. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speeds.

SAFETY

Operator Safety

S Always have the ATV inspected by an authorized Polaris dealer if

it’s been involved in an accident.

S Never operate on hills too steep for the ATV or for your abilities.

Practice on smaller hills before attempting larger hills.

S Always follow proper procedures for climbing hills. Check the ter-

rain carefully before ascending a hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. Never go over the top of a hill at high speed.

S Always follow proper procedures for going downhill and for braking

on hills. Check the terrain carefully before you start down a hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle, which would cause the vehicle to lean sharply t o one side. Travel straight down the hill when possible.

S Always follow proper procedures for crossing the side of a hill.

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

S Always use proper procedures if you stall or roll backwards while

climbing a hill. To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Always dismount on the uphill side, or to either side if the ATV is pointed straight uphill. Turn the ATV around and remount following the procedure described in this manual.

S Always check for obstacles before operating in a new area. Never

attempt to operate over large obstacles, such as rocks or fallen t rees. Always follow proper procedures when operating over obstacles as described in this manual.

S Always be careful of skidding or sliding. On slippery surfaces like

ice, travel slowly and use extra caution to reduce the chance of skidding or sliding out of control.

S Avoid operating the ATV through deep or fast-flowing water. If it’s

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

SAFETY

Operator Safety

S Wet brakes may have reduced stopping ability. Test the brakes after

leaving water. If necessary, apply them lightly several times to allow friction to dry out the pads.

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

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

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

always maintain proper tire pressure.

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

sories.

S Never exceed the stated load capacity for your ATV. Cargo must be

properly distributed and securely attached. Reduce speed and follow the instructions in this manual for carrying cargo or towing. Allow a greater distance for braking.

FOR MORE INFORMATION ABOUT ATV SAFETY ,call the Consumer Product Safety Commission at 1-800-638-2772, or call Polaris at 1-800-342-3764.

Equipment Modifications

We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes. Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury.

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

NOTE: The addition of certain accessories, including (but not limited

to) mowers, blades, tires, sprayers, or large racks, may change the handling characteristics of the vehicle. Use only Polaris-approved accessories, and familiarize yourself with their function and effect on the vehicle.

SAFETY

Operator Safety

WARNING

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

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

HOW TO AVOID THE Beginning and inexperienced operators should complete the

certified training course offered by Polaris. Operators should regularly practice the skills learned in the course and the operating techniques described in the owner’s manual.

For more information about the training course, contact an authorized ATV dealer or call Polaris at 1-800-342-3764.

HAPPEN

HAZARD

WARNING

POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN Severe injury and/or death could occur if a child under the

minimum age recommendation operates an ATV. Even though a child may be within the recommended age group

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

HOW TO AVOID THE No one under the age of 16 should operate a Polaris ATV.

HAPPEN

HAZARD

Operator Safety

WARNING

POTENTIAL HAZARD Carrying a passenger on an

ATV. WHAT CAN Carrying a passenger

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

HOW TO AVOID THE Never carry a passenger. The purpose of the long seat is to

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

HAPPEN

HAZARD

WARNING

POTENTIAL HAZARD Operating an ATV

on paved surfaces, including sidewalks, paths, parking lots, and driveways.

WHAT CAN ATV tires are designed for

off-road use. Operating on paved surfaces may seriously affect the handling and control of the ATV and could result in loss of control, accident, and/or injury.

HOW TO AVOID THE Avoid operating the ATV on pavement. If it’s unavoidable, travel

slowly and avoid sudden turns or stops.

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Operating this ATV on

public streets, roads or highways.

WHAT CAN The ATV could collide

with another vehicle. HOW TO AVOID THE Never operate the ATV on any

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

HAPPEN

HAZARD

WARNING

POTENTIAL HAZARD Operating this ATV without

wearing an approved helmet, eye protection and protective clothing.

WHAT CAN Operating an ATV without

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

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

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

boots, long-sleeved shirt or jacket, and long pants.

HAPPEN

HAZARD

Operator Safety

WARNING

POTENTIAL HAZARD Operating the ATV after consuming

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

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

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

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

ATV.

HAPPEN

HAZARD

WARNING

POTENTIAL HAZARD Operating the ATV at excessive speeds. WHAT CAN Excessive speed increases the operator’s chance of losing

control of the ATV, which can result in an accident. HOW TO AVOID THE Always operate the ATV at a speed that’s proper for the terrain,

visibility and operating conditions, and your experience.

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Attempting wheelies, jumps

and other stunts. WHAT CAN Attempting stunts increases

the chance of an accident, including an overturn.

HOW TO AVOID HAZARD

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

HAPPEN

THE

WARNING

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

equipment damage. HOW TO AVOID THE Always inspect your ATV before each use to make sure it’s in

safe operating condition. Always follow the inspection and maintenance procedures and

schedules described in the owner’s manual.

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests

during operation. WHAT CAN Removing even one hand or foot can reduce ability to control the

vehicle or could cause loss of balance and ejection from the ATV. If the operator’s foot is not firmly planted on the footrest, it could

come into contact with the rear wheels and lead to accident or injury.

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

footrests of the ATV during operation.

HAPPEN

HAZARD

WARNING

POTENTIAL HAZARD Failure to use extra

caution when operating the ATV on unfamiliar terrain.

WHAT CAN Unfamiliar terrain may

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

HOW TO AVOID THE Travel slowly and use extra caution when operating on unfamiliar

terrain. Always be alert to changing terrain conditions.

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Failure to use extra

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

WHAT CAN Operating on excessively

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

HOW TO AVOID THE Do not operate on excessively rough, slippery or loose terrain

until you’ve learned and practiced the skills necessary to control the ATV on such terrain.

Always use extra caution on rough, slippery or loose terrain.

HAPPEN

HAZARD

WARNING

POTENTIAL HAZARD Turning improperly. WHAT CAN Improper turns could cause loss of control and lead to a collision

or overturn. HOW TO AVOID THE Always follow proper procedures for turning as described in the

owner’s manual. Practice turning at slow speeds before attempting to turn at faster

speeds. Never turn at excessive speed.

HAPPEN

HAZARD

Operator Safety

WARNING

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

Never operate the ATV on hills steeper than 25_. Practice on smaller hills before attempting large hills.

HAPPEN

HAZARD

WARNING

POTENTIAL HAZARD Climbing hills improperly. WHAT CAN Improper hill climbing could

cause loss of control or overturn.

HOW TO AVOID HAZARD

Always follow proper procedures for climbing hills as described in the owner’s manual.

Always check the terrain carefully before ascending any hill.

Never operate the ATV on hills steeper than 25_. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly while traveling uphill. The ATV

could flip over backwards. Never go over the top of any hill at high speed. An obstacle, a

sharp drop, or another vehicle or person could be on the other side of the hill.

HAPPEN

THE

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Traveling downhill

improperly. WHAT CAN Improperly descending a hill

could cause loss of control or overturn.

HOW TO AVOID HAZARD

Always follow proper procedures for traveling down hills as described in the owner’s manual. NOTE: A special technique is required when braking while traveling downhill. See page 61.

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

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

HAPPEN

THE

Operator Safety

WARNING

POTENTIAL HAZARD Improperly crossing hills and

turning on hills. WHAT CAN Improperly crossing or

turning as hills could cause loss of control or overturn.

HOW TO AVOID HAZARD

Neverattempttoturnthe ATV around on any hill until you’ve mastered the turning technique (on level ground) as described in the owner’s manual. See page 62. Use extra caution when turning on any hill.

Avoid crossing the side of a steep hill. When crossing the side of a Always follow proper procedures as described in the owner’s

manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.

HAPPEN

THE

hill:

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Stalling, rolling backwards

or improperly dismounting while climbing a hill.

WHAT CAN The vehicle could overturn. HOW TO AVOID

HAZARD Maintain steady speed

when climbing a hill. If all forward speed is Keep your weight uphill. Apply the brakes. Lock the parking brake when fully stopped. If the ATV begins rolling Keep weight uphill. Never apply engine power. Never apply the rear brake while rolling backwards. Apply the single-lever brake gradually. When fully stopped, apply the rear brake as well, and then lock

the parking brake. Dismount on uphill side, or to either side if ATV is pointed straight

uphill. Turn the ATV around and remount, following the procedure

described in the owner’s manual. See page 62.

HAPPEN

THE

lost:

backwards:

Operator Safety

WARNING

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

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

HAPPEN

HAZARD

WARNING

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

caution to reduce the chance of skidding or sliding out of control.

HAPPEN

HAZARD

SAFETY

WARNING

POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN The ATV could collide with an obstacle or person, resulting in

severe injury. HOW TO AVOID THE Before shifting into reverse gear, always check for obstacles or

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

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Operating the ATV through deep or fast-flowing water. WHAT CAN Tires may float, causing loss of traction and loss of control, which

could lead to an accident or overturn. HOW TO AVOID THE Avoid operating the ATV through deep or fast-flowing water. If it’s

unavoidable to enter water that exceeds the recommended maximum depth (see page 64), travel slowly, balance your weight carefully, avoid sudden movements, and maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make sudden throttle changes.

Wet brakes may have reduced stopping ability. Always test the brakes after leaving water. If necessary, apply them several times to let friction dry out the pads.

HAPPEN

HAZARD

WARNING

POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or

uneven tire pressure. WHAT CAN Use of improper tires, or operation of the ATV with improper or

uneven tire pressure, could cause loss of control or accident. HOW TO AVOID THE Always use the size and type of tires specified for the ATV. Always maintain proper tire pressure as specified.

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

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

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

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

HAPPEN

HAZARD

WARNING

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

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

greater distance for braking. Always follow the instructions in the owner’s manual for carrying

cargo or pulling a trailer. See page 54.

HAPPEN

HAZARD

WARNING

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

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

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use.

WARNING

After any overturn or accident, have a qualified service dealer inspect the entire vehicle for possible damage, including (but not limited to) brakes, throttle and steering systems.

WARNING

Safe operation of this rider-active vehicle requires good judgement and physical skills. Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control, which could result in severe injury or death.

CAUTION

Exhaust system components are very hot during and after use of the vehicle. Hot components can cause serious burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system. Use caution when traveling through tall grass, especially dry grass.

CONTROLS

Electrical Switches

WARNING

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

Mode/Reverse Override Switch (1) - This vehicle is equipped with a reverse speed limiter system. To gain additional power while backing, depress the override switch.

NOTE: The override switch also allows activation of AWD in reverse,

if the AWD switch is on. This switch is also used to toggle through the different modes of the rider information center. See page 44.

Engine Stop Switch (2) - The engine will

OFFOFF

not start or run when the switch is in the

RUN

OFF position. Its purpose is to provide the operator with a quick means of engine shutdown in case of an emergency.

Main Switch (3) - To start the engine, slide

the stop switch t o the center RUN position and turn the main key switch clockwise past the ON position. Release the key when the engine starts.

NOTE: Both the main switch and the emergency engine stop switch

will shut off all electrical power to the vehicle, including lights. To stop the engine, slide the stop switch either right or left to the OFF position.

Front/Rear Winch Switch (4) - Use the switch on the pod to select either the front or rear winch.

Winch Operation Switch (5) - After selecting either the front or rear winch with the switch on the pod, use the handlebar switch to operate the winch. Winch operation instructions can be found in The Basic Guide to Winching Techniques, provided by the winch manufacturer.

CONTROLS

WARNING

Operating an ATV with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death.

Never start or operate an ATV with a sticking or improperly operating throttle. Always contact your dealer for service if throttle problems arise.

Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation. Always check the lever for free movement and return before starting the engine. Also check occasionally during operation.

Throttle Lever

Engine speed and vehicle movement are controlled by pressing the throttle lever (1). The throttle lever is spring loaded. Engine speed returns to idle when the lever is released.

This ATV is equipped with Polaris Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the throttle cable should stick in an open position when the operator releases the throttle lever, the engine will stop, and power to the rear wheels will cease.

WARNING

The Electronic Throttle Control (ETC) stops the engine in the event of a throttle system malfunction and is provided for your safety. Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms.

CONTROLS

Light Switches

The light switch is located on the left handlebar. It’s used to turn the lights on and off and to switch the lights from HI to LO.

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

and the shut-off switch is in the RUN position.

WARNING

Operating the ATV on streets or roads, especially in darkness, could result in an accident and serious injury or death.

Your ATV is not equipped with highway-approved lights. It’s designed for and must be used for off-road use only. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness.

Brake Lever

The front and rear brakes are applied by squeezing the brake lever (1) toward the handlebar. The front and rear brakes are hydraulically activated disc type brakes that are activated by only one lever.

Always test brake lever travel and master cylinder fluid level before riding. When squeezed, the lever should feel firm. Any sponginess would indicate a possible fluid leak or low master cylinder fluid level, which must be corrected before riding. Contact your dealer for proper diagnosis and repairs.

WARNING

Operating the ATV with a spongy brake lever can result in loss of braking, which could cause an accident.

Never operate the ATV with a spongy-feeling brake lever.

CONTROLS

Master Cylinder

The brake fluid in the master cylinder (1), which is located on the left handlebar, should be checked before each ride. The fluid level can be seen through an indicator window (2) on the top of the master cylinder. This eye will appear dark when the fluid level is full. When fluid needs to be added, the eye will be clear.

NOTE: When checking the fluid level, the ATV must be on level

ground with the handlebars straight. If the fluid level is low add DOT 3 brake fluid only. See page 114 for the part numbers of Polaris products.

WARNING

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

CONTROLS

Parking Brake

WARNING

Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating.

Locking th e Parking Brake

1. Place the transmission in PARK.

2. Squeeze and release the brake lever (1) two or three times, then squeeze and hold.

3. Push the park brake lock (2) forward to engage the brake. Release the brake lever.

4. To release the parking brake lock, squeeze and release the brake lever. It will return to its unlocked position.

Important Safeguards

S The parking brake m ay relax if left on for a long period of time. Al-

ways block the wheels to prevent rolling.

S Always block the wheels on the downhill side of the ATV if leaving

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

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

hill. Always block the wheels to prevent rolling.

CONTROLS

Auxiliary Brake

WARNING

Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death.

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

Your Polaris ATV has an auxiliary brake (1) for added safety. It’s located on the inside of the right floor board and is operated by the right foot. The auxiliary brake serves as a backup to the main brake system if the main system becomes inoperative.

If the rear wheels slide while using 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 or near the auxiliary brake. Maintain the fluid level between the maximum and minimum marks.

CONTROLS

Choke

The choke assists in starting a cold engine. Refer to the engine starting procedure on page 52 for correct choke and throttle settings during starting.

Fuel Requirements

Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane.

Fuel Valve

The fuel valve (1) is located on the left side panel.

OFF: Turn the fuel valve off for vehicle storage and when transporting.

REAR TANK: We recommend using the rear tank fuel supply first. Switch to the front tank when the rear tank is empty. It will be easier to monitor remaining fuel at the front tank gauge.

FRONT TANK: Use the front tank fuel supply when the rear tank is empty.

OFF

REAR

TAN K

FRONT

TAN K

NOTE: There is no reserve fuel

supply on this vehicle. When both fuel tanks are empty, the vehicle will not operate.

Fuel T anks

The front fuel tank filler cap (2) is located directly below the handlebar. The rear fuel tank and filler cap (3) are located behind the seat, under the rear rack.

Fuel Filter

The in-line fuel filter should be replaced by your dealer after every 100 hours of operation, or annually. Do not attempt to clean the fuel filter.

CONTROLS

Automatic Transmission Gear Selector

The transmission gear selector (1) is located on the right side of the vehicle.

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

H L

N R P

CAUTION

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

To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear.

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

Belt Life

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

FEATURES

Recoil Starter

If the battery has been drained or damaged and cannot start the engine, use of the recoil starter (1) will allow vehicle operation until repairs can be made. The recoil starter is located on the right side of the machine.

Polaris 4-cycle engines are equipped with automatic decompressors. This makes recoil starting possible by reducing the amount of compression during starting. The decompressor senses when the engine is spinning fast enough to start and restores compression when running.

1. Position the vehicle on a level surface and lock the parking brake (see page 37).

2. Shift the transmission into neutral.

3. Make sure the engine stop switch is set to RUN and the main key switch is in the ON position.

NOTE: If the engine is cold, use the choke as outlined on page 52.

4. Grasp the recoil starter rope handle (2) firmly and pull slowly so you can feel the engine strokes.

NOTE: Every other stroke will be a “compression stroke” and will

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

5. Allow the recoil rope to rewind into the recoil assembly, t hen pull the rope abruptly and forcefully to start the engine.

6. Repeat steps 4-5 if necessary.

CAUTION

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

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

FEATURES

Run-Flat Tires

This ATV is equipped with run-flat tires, which permit limited operation with a flat tire. However, ATV load capacity is reduced when tire air pressure is lost. Remove cargo from the racks and do not tow a load with flat tires. Vehicle characteristics, including braking and handling, may also be affected by operating with flat tires. If you must operate the vehicle with a flat tire, drive no further and no faster than necessary, and travel on smooth and level terrain whenever possible.

WARNING

Failure to reduce travel distance, vehicle speed and cargo weight when air pressure is lost in run-flat tires could result in loss of control or tire damage. This could lead to serious injury or death.

If you must operate the vehicle with flat tires, remove all cargo and towed loads from the ATV, and do not exceed 50 miles (80 km)at25MPH(40km/h).

Have the tire(s) inspected by an authorized Polaris dealer as soon as possible and before further use.

Winches

Your vehicle is equipped with both a front (1) and a rear (2) winch. These winches operate independently. Use the pod switch to select one of the winches. Use the handlebar switch to operate the selected winch.

Refer to the winch manufacturer’s Basic Guide to Winching Techniques, provided with your ATV, for complete winch operation instructions.

FEATURES

All Wheel Drive (AWD) System

Polaris 4-wheel drive ATVs are equipped with a unique, Polaris-exclusive, All Wheel Drive (AWD) system, which is activated by a switch (1) on the right handlebar. When the switch is off, the ATV is in 2 wheel drive at all times. When the switch is on, the ATV is in AWD and the A WD indicator light in the instrument cluster will be on.

When in AWD, the front gearcase will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the front gearcase will automatically disengage.

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

AWD switch is on. See page 33.

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

Engaging Front Gearcase

The AWD switch may be turned on or off while the vehicle is moving. Initially, the vehicle’s electronic system will not enable the AWD until the engine RPM is below 3100. Once enabled, the AWD remains enabled until the AWD switch is turned off. If the switch is t urned off while the front gearcase i s moving, it will not disengage until the rear wheels regain traction.

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

CAUTION

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

FEATURES

Instrument Cluster

Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster m easures distance in miles or kilometers as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV’s speed to approximately 7-9 mph. Refer to page 33 for additional information.

1. Rider Information C enter

2. Speedometer needle - in addition to showing vehicle speed, the needle flashes when a warning condition exists.

3. Speedometer

CAUTION

To prevent damage, wash the vehicle by hand or with a garden hose using mild soap. Do not use alcohol to clean the instrument cluster. Immediately clean off any gasoline that splashes on the instrument cluster. Do not allow insect sprays to come into contact with the lens.

FEATURES

Instrument Cluster

Rider Information Center

The rider information center is located in the instrument cluster. All segments will light up for 2.5 seconds at start-up.

NOTE: If the instrument cluster fails to illuminate, a battery

over-voltage may have occurred and the instrument cluster may have shut off to protect the cluster’s electrical system. If this occurs, take the ATV to your Polaris dealer for proper diagnosis.

1. Gear Indicator - As the shift lever is moved, this indicates the gear the transmission is in:

H = High Range

L = Low Range N = Neutral R = Reverse P=Park

2. AWD Indicator - This indicator illuminates when the electrical portion of the AWD system is enabled.

3. Engine Hour Display Indicator

4. Service Interval/Diagnostic Mode Indicator

5. Low Battery and Over Voltage - This warning usually indicates that the ATV is being operated at an RPM too low to keep the battery charged. A low battery warning may also occur under normal operation if the machine is at idle and high electrical load (lights, cooling fan, accessories) is applied. Driving at a higher RPM or connecting a battery charger will usually clear the warning.

6. Odometer/Tachometer/Tripmeter/ Hour Meter

7. Fuel Gauge - The segments of the fuel gauge indicate the level of fuel in the front tank only. Since use of the rear tank is recommended for normal operation, the rear tank may already be empty. Refuel immediately if the last segment of the fuel gauge clears.

8. Check Engine Warning Indicator - The word HOT will display alphanumerically when the engine is overheating. Do not continue to operate the ATV if this warning appears or serious engine damage could result.

9. Mode Indicator

FEATURES

Instrument Cluster

Rider Information Center

The rider information center has 4 standard modes: Mode 1 - Odometer Mode 2 - Tripmeter Mode 3 - Total Service Hours Mode 4 - Tachometer The reverse override button on the left handlebar is also the mode

button.

NOTE: If using the mode button to program the rider information

center, or to toggle through the options, the machine cannot be in reverse.

Mode 1 - Odometer

The odometer records the miles traveled by the ATV.

Mode 2 -Trip Meter

The trip meter records the miles traveled by the ATV on each trip if it’s reset before each trip. To reset the trip meter, select the trip meter mode. Press and hold the mode button (override button) until the t otal changes to 0.

NOTE: In the Rider Information Center, the trip meter display

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

Mode 3 - Hour Meter

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

Mode 4 - Tachometer

The engine RPM is displayed digitally.

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

normal because of changes in humidity, temperature, elevation and electrical loads.

FEATURES

Instrument Cluster

Rider Information Center

Diagnostic Mode

The diagnostic mode is for informational purposes only. Please return your ATV to your dealer for all major repairs.

As long as the gauge is in the diagnostic mode, the wrench icon will remain lit.

To leave the diagnostic mode, turn the key switch off and on. Any movement of the tires will also take the machine out of the diagnostic mode.

To enter the diagnostics mode:

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

2. Set the park brake and shift t he transmission to neutral.

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

4. Release the switch as soon as the display is activated.

The initial screen display refers to t he software version installed in your ATV. This information is displayed briefly.

Use the mode/reverse override button to toggle through the diagnostic screens.

Screen 1: Battery voltage

Screen 2: Tachometer

Screen 3: AWD diagnostic

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

Screen 4: Gear circuit diagnostic This screen displays the resistance value (in ohms) being read at the

gear switch input of the gauge.

FEATURES

Instrument Cluster

Rider Information Center

Diagnostic Mode

Screen 5: Programmable service interval The purpose of t he programmable service interval is to provide the

consumer and dealer with a convenient reminder for routine maintenance. When your vehicle leaves the factory, this feature is set at 50 hours. You must enable t he programmable service interval before it can be used.

Once the service interval mode is set with the hours when service is due, the hours of actual engine operation are subtracted from the set hours until 0 is reached. When the counter reaches 0, the wrench icon will flash quickly for 5 seconds each time the vehicle is started as a reminder that the periodic maintenance is due.

To set the hours, press and hold the mode/override button until the wrench icon flashes. When it begins to flash, release the button. The setting will increase by one hour each time the button i s pressed. Pressing and holding the button will allow the numbers to escalate much faster. When the desired time increment is displayed, release the button and wait for the wrench to stop flashing. When the wrench stops blinking, your service hours are set.

NOTE: If you scroll past the intended number, hold the button down

If the service interval is enabled on your ATV and you wish to turn it off, toggle to the service interval mode. Press and hold the mode button for approximately 7 seconds until the word OFF appears in the Rider Information Center.

Screen 6: Miles/Kilometers toggle The display in the tripmeter and odometer can be changed to display

either kilometers or miles. The current display mode will be shown as KM or MP. To change, hold in t he mode button until the letters flash, then press and release the button once. When the display stops flashing, the mode has been set.

until the count turns over to 0. You can then reset the number.

OPERATION

Fuel Safety

WARNING

Gasoline is highly flammable and explosive under certain conditions.

S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a well

ventilated area.

S Do not smoke or allow open flames or sparks in or near the

area where refueling is performed or where gasoline is stored.

S Do not overfill the tank. Do not fill the tank neck. S If gasoline spills on your skin or clothing, immediately wash it off

with soap and water and change clothing.

S Never start the engine or let it run in an enclosed area.

Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time.

S Turn the fuel valve off whenever the ATV is stored or parked.

WARNING

The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.

Operate this vehicle only outdoors or in well-ventilated areas.

OPERATION

Break-In Period

The break-in period for your new Polaris ATV is defined as 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 will result in more efficient performance and longer life for the engine. Perform the following procedures carefully.

CAUTION

Excessive heat build-up during the first three hours of operation will damage close-fitted engine parts. Do not operate at full throttle or high speeds for extended periods during the first three hours of use.

CAUTION

Mixing brands or using a non-recommended oil may cause serious engine damage. We recommend the use of Polaris Premium 4 synthetic Oil or another 0W-40 API certified SH oil. Never substitute or mix oil brands.

1. Fill the fuel tanks with gasoline. See page 39.

2. Check the oil reservoir level on the dipstick. See page 75. Add oil if necessary to maintain the level between the safe and add marks.

3. Drive slowly at first. Select an open area that allows room to familiarize yourself with vehicle operation and handling.

4. Vary the throttle positions. Do not operate at sustained idle.

5. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride inspection checklist. See page 51.

6. Pull only light loads.

7. During the break-in period, change both the oil and the filter at 20 hours, 200 miles, or one month, whichever comes first.

OPERATION

Pre-Ride Inspection

WARNING

If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it’s in proper operating condition.

Pre-Ride Checklist

Item Remarks See

Page

Brake system / lever travel Ensure proper operation 35, 84

Brake fluid Ensure proper level 36

Auxiliary brake Ensure proper operation 38

Front suspension Inspect, lubricate if necessary 73

Rear suspension Inspect, lubricate if necessary 73

Steering Ensure free operation --

Tires Inspect condition and pressure 87

Wheels / fasteners Inspect, ensure fastener tightness 88

Frame nuts, bolts, fasteners Inspect, ensure tightness --

Fuel and oil Ensure proper levels 75

Coolant level (if applicable) Ensure proper level --

Coolant hoses (if applicable) Inspect for leaks --

Throttle Ensure proper operation 34, 111

Indicator lights / switches Ensure operation 35

Engine stop switch Ensure proper operation 33

Air filter, pre-filter Inspect, clean 89

Air box sediment tube Drain deposits whenever visible --

Headlamp Check operation, apply Polaris dielec-

tric grease when lamp is replaced

Brake light / tail lamp Check operation, apply Polaris dielec-

tric grease when lamp is replaced

Riding gear Wear helmet, goggles, protective

clothing

OPERATION

Starting the Engine

Starting a Cold Engine

WARNING

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

1. Place the transmission in PARK and lock the parking brake.

2. Turn the fuel valve on.

3. Sit on the vehicle and pull the choke knob (1) out until it stops.

NOTE: The variable choke is fully on

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

4. Turn the engine stop switch to RUN.

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

5. Turn the ignition key past the ON position to engage the starter. Activate the starter for a maximum of five seconds, releasing the key when the vehicle starts. If the engine does not start, release the starter and wait five seconds. Activate the starter for another five seconds if necessary. Repeat this procedure until the engine starts.

6. If the engine slows or stops, position the choke knob half way in to allow proper engine warm-up.

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

CAUTION

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

OPERATION

Starting the Engine

Starting a Warm Engine

Warm engines do not normally require the use of the choke. Using the choke can cause the spark plug to become wet fouled.

1. Position the vehicle on a level surface with the transmission in PARK.

2. Lock the parking brake. Turn the fuel valve on, sit on the vehicle, and turn the engine stop switch to RUN.

3. If the engine has cooled to a point where it does not readily start, intermittent use of the choke (knob pulled half way out) may be necessary.

4. If the engine is over-choked when warm, depress the throttle lever fully while cranking to aid in starting.

5. Release the throttle lever immediately after the engine starts. If the engine does not start and all conditions are favorable, change the sparkplugandtryagain.

Cold Weather Operation

If the ATV is used year-round, check the oil level frequently. A rising oil level could indicate the accumulation of contaminants such as water or excess fuel in the bottom of the oil tank. Water in the bottom of the tank can lead to engine damage and must be drained. W ater 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.

OPERATION

Driving Safely

Hauling Cargo

1/3

Your ATV has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warning labels on the vehicle, and never exceed the weight capacities outlined in the specifications section of the owner’s manual and on the safety decals.

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

Belt Life

Use low forward gear when hauling or towing heavy cargo to extend belt life.

2/3

OPERATION

Driving Safely

Hauling Cargo

WARNING

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

S REDUCE SPEED AND ALLOW GREATER DISTANCES FOR

BRAKING WHEN HAULING CARGO.

S CARGO WEIGHT DISTRIBUTION should be 1/3 on the front

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

S CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE.

Carrying loads high on the racks raises the center of gravity of the vehicle and creates a less stable operating condition.

S SECURE ALL LOADS BEFORE OPERATING. Unsecured

loads can create unstable operating conditions, which could result in loss of control of the vehicle.

S OPERATE ONLY WI TH STABLE AND SAFELY ARRANGED

LOADS. When handling off-centered loads that cannot be centered, securely fasten the load and operate with extra caution. Always attach the tow load to the hitch point designated for your vehicle.

S HEAVY LOADS CAN CAUSE BRAKING AND CONTROL

PROBLEMS. Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations that may require backing downhill.

S USE EXTREME CAUTION when operating with loads that

extend over the rack sides. Stability and maneuverability may be adversely affected, causing the vehicle to overturn.

S DO NO T BLOCK THE FRONT HEADLIGHT BEAM when

carrying loads on the front rack.

S DO NO T TRAVEL FASTER THAN THE RECOMMENDED

SPEEDS. Vehicle should never exceed 10 mph (16 kph) while towing a load on a level grass surface. Vehicle speed should never exceed 5 mph (8 kph) when towing loads in rough terrain, while cornering, or while ascending or descending a hill.

OPERATION

Driving Safely

Driving Procedures

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

2. Start the engine and allow it to warm up, then shift the transmission into gear.

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

4. Release the parking brake.

5. Slowly depress the throttle with your right thumb and begin driving. Vehicle speed is controlled by the amount of throttle opening.

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

OPERATION

Driving Safely

Making Turns

Your ATV is equipped with a rear axle that drives both rear wheels equally at all times. This means that the wheel on the outside of the t urn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly. To turn, steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. This technique alters the balance of traction between the rear wheels, allowing the turn to be made smoothly. The same leaning technique should be used for turning in reverse.

NOTE: Practice making turns at slow speeds before attempting to

turn at faster speeds.

WARNING

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

OPERATION

Driving Safely

Driving on Slippery Surfaces

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

1. Slow down when entering slippery areas.

2. Engage AWD before wheels begin to lose traction.

3. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns, which can cause skids.

4. Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward.

CAUTION

Severe damage to drive train may occur if the AWD is engaged while the wheels are spinning. Always allow the rear wheels to stop spinning before engaging AWD, or engage AWD before wheels begin to lose traction.

WARNING

Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control, accident, and serious injury or death.

Never apply the brakes during a skid. Do not operate on excessively slippery surfaces. Always reduce speed and use additional caution.

OPERATION

Driving Safely

Driving Uphill

25_ Maximum

Whenever traveling uphill, follow these precautions:

1. Always travel straight uphill.

2. Avoid steep hills (25_ maximum).

3. Keep both feet on the footrests.

4. Transfer your weight forward.

5. Proceed at a steady rate of speed and throttle opening.

6. Remain alert and be prepared to take emergency action. This may include quick dismounting of the vehicle.

WARNING

Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn and result in serious injury or death.

Avoid climbing steep hills (25_ maximum). Use extreme caution when operating on hills, and follow proper

operating procedures outlined in the owner’s manual.

OPERATION

Driving Safely

Sidehilling

WARNING

Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner’s manual.

Sidehilling can be the most dangerous type of driving encountered and should be avoided if at all possible. If you do enter into a situation where sidehilling is necessary, follow these precautions:

1. Slow down.

2. Lean into the hill, transferring your upper body weight toward the hill while keeping your feet on the footrests.

3. Steer slightly into the hill to maintain vehicle directions.

NOTE: If the vehicle begins to tip, quickly turn the front wheel

downhill, if possible, or dismount on the uphill side immediately!

OPERATION

Driving Safely

Driving Downhill

Whenever descending a hill, follow these precautions:

1. Proceed directly downhill.

2. Transfer your weight to the rear of the vehicle.

3. Slow down.

4. Apply t he brakes slightly toaidinslowing. Familiarize yourself with operation of the auxiliary brake in the event

loss of normal service brakes occurs.

WARNING

Excessive speed can cause loss of control and lead to serious injury or death. Always operate slowly when traveling downhill.

OPERATION

Driving Safely

Turning Around on a Hill

WARNING

Improper hill climbing procedures could cause loss of control or overturn and result in serious injury or death.

Avoid climbing steep hills (25_ maximum). Use extreme caution when operating on hills, and follow proper

operating procedures outlined in the owner’s manual.

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

8 ft. (2.4 m)

OPERATION

Driving Safely

Turning Around on a Hill

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

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

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

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

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

6. Lock the parking brake and remount the vehicle from the uphill side, keeping body weight uphill.

7. Restart the engine with the t ransmission 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.

OPERATION

Driving Safely

Driving Through Water

Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests (1). Follow t hese procedures when operating through water:

1. Determine water depths and current before crossing.

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

3. Proceed slowly, avoiding rocks and obstacles if possible.

4. After crossing, dry the brakes by applying light pressure to the lever until braking action is normal.

After running the vehicle in water, it’s critical to have it serviced as outlined in the maintenance chart. See page 69. The following areas need special attention: engine oil, transmission oil, front and rear gearcases, and all grease fittings.

CAUTION

Major engine damage can result if the vehicle is not thoroughly inspected after operation in water. Perform the services outlined in the maintenance chart.

If your vehicle becomes immersed or is operated in water that exceeds the footrest level, take it to your dealer for service before starting the engine.

NOTE: Avoid operating the vehicle through deep or fast-flowing

water. If you cannot avoid water that exceeds the recommended maximum depth, go slowly, balance your weight carefully, avoid sudden movements, and maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make sudden throttle changes.

If your vehicle becomes immersed, and it’s impossible to take it to a dealer before starting it, follow the steps described on page 95. Have the vehicle serviced by your dealer at the first opportunity.

OPERATION

Driving Safely

Driving Over Obstacles

Be alert! Look ahead and learn to read the terrain you’re traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches.

WARNING

Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. Not all obstacles are immediately visible. Travel with caution in unfamiliar terrain.

OPERATION

Driving Safely

Driving in Reverse

Follow these precautions when operating in reverse:

1. Always avoid backing downhill.

2. Back slowly.

3. When in reverse, apply the brakes lightly for stopping.

4. Avoid turning at sharp angles in reverse.

5. Never open the throttle suddenly while backing.

WARNING

Failure to use caution when operating in reverse can result in serious injury or death. Before shifting into reverse, always check for obstacles or people behind the vehicle. When it’s safe to proceed, back slowly.

Do not use the override switch unless additional power is required for vehicle movement. Use with caution.

Avoid backing on inclines, and avoid turning at sharp angles.

NOTE: Your Polaris ATV is equipped with a reverse speed limiter.

The override button should be used with caution as rearward vehicle speed is greatly increased. Do not operate at wide open throttle. Open the throttle just enough to maintain a desired speed.

CAUTION

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

OPERATION

Driving Safely

ParkingonanIncline

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

1. Turn the engine off.

2. Place the transmission in PARK.

3. Set the parking brake.

4. Always block the rear wheels on the downhill side as shown in the illustration.

5. Shut off the fuel supply.

EMISSION CONTROL SYSTEMS

Noise Emission Control System

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

Crankcase Emission Control System

This engine is equipped with a closed crankcase system. Blow–by gases are forced back to the combustion chamber by the intake system. The system does not allow the blow–by gases to enter the atmosphere.

Exhaust Emission Control System

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

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

The emissions label is located on the recoil cover.

WARNING

The installation of devices that effectively increase exhaust emissions beyond their legal limits will void all manufacturer warranties and may violate laws governing the registration and operation of this vehicle.

Spark Arrestor

Your Polaris vehicle has a spark arrestor that was tested and approved in accordance with the USDA Forest Service Standard 5100–1C. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands.

Electromagnetic Interference

This spark ignition system complies with Canadian ICES--002.

MAINTENANCE AND LUBRICATION

Accessories

Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights. See your Polaris dealer.

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 m aintenance 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.

NOTE: Service and adjustments are critical. If you’re not familiar

with safe service and adjustment procedures, have a qualified dealer perform these operations.

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

Severe Use Definition

S Frequent immersion in mud, water or sand S Racing or race-style high RPM use S Prolonged low speed, heavy load operation S Extended idle S Short trip cold weather operation

Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause or see your dealer.

Maintenance Chart Key

" Perform these procedures more frequently for vehicles subjected to

severe use.

E Emission C ontrol System Service (California)

J Have an authorized Polaris dealer perform these services.

WARNING

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

MAINTENANCE AND LUBRICATION

onpage5

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

Item Maintenance Interval

(whichever comes first)

Hours Calendar Miles

Steering -- Pre-Ride --

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 --

(Km)

Make adjustments as needed. See Pre-Ride Checklist on page 51.

Remarks

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

Air box sediment

tube

Coolant -- Daily -- Check level daily, change

Headlamp/tail lamp

Air filter,

main element

Recoil housing -- Weekly -- Drain water as needed,

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

" J

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

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

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.

-- Daily -- Drain deposits when visible

coolant every 2 years

-- Daily -- Check operation

-- Weekly -- Inspect; replace as needed

check often if operating in wet conditions

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

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

E Emission Control System Service (California)

J Have an authorized Polaris dealer perform these services.

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Item Maintenance Interval

(whichever comes first)

Hours Calendar Miles

General

lubrication

Carburetor float bowl

Throttle Cable/

ETC Switch

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

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

50 H 6M 500 (800) Drain bowl periodically and

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

Carburetor air

intake ducts/ flange

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

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

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

50 H 6M 500 (800) Inspect ducts for proper

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

(Km)

cables, etc.

prior to storage

replace if necessary

sealing/air leaks

needed

seasonally; pressure test system yearly

change at one month

Remarks

Oil tank vent hose

(if equipped)

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

100 H 12 M 1000 (1600) Inspect routing, condition

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

Radiator

(if applicable)

Cooling hoses

(if applicable)

Engine mounts 100 H 12 M 1000 (1600) Inspect

Exhaust muffler/ pipe

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

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

100 H 12 M 1000 (1600) Inspect for leaks

100 H 12 M 1000 (1600) Inspect

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

surfaces

E Emission Control System Service (California)

J Have an authorized Polaris dealer perform these services.

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Item Maintenance Interval

(whichever comes first)

Hours Calendar Miles

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

(Km)

Remarks

Ignition Timing 100 H 12 M 1000 (1600) Inspect

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

Clutches (drive

and driven)

Front wheel

bearings

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

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

Winch System -- See The Basic Guide to

Idle speed -- Adjust as needed

Toe adjustment -- Inspect periodically; adjust

Headlight aim -- Adjust as needed

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

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

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

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

parts

Winching Techniques,provided by the winch manufacturer.

when parts are replaced

E Emission Control System Service (California)

J Have an authorized Polaris dealer perform these services.

MAINTENANCE AND LUBRICATION

Lubrication Guide

Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 69. Items not listed in the chart should be lubricated at the General Lubrication interval.

Lubrication Guide Key

" More often under severe use

L Polaris Premium All Season Grease or grease conforming to NLGI

No. 2, such as Conoco Superlube M or Mobilegrease Special

F Use Polaris Premium U-Joint Lube every 500 miles, before long

periods of storage, or after pressure washing or submerging.

Item Lube Method

Engine Oil Polaris Premium 4 Synthetic

Brake Fluid DOT 3 Only Maintain level between fill

Transmission Oil Polaris Premium AGL Synthetic

Front Gearcase Oil Premium Demand Drive Hub

Rear Gearcase Oil Premium ATV Angle Drive Fluid See page 79.

Front Prop Shaft Yoke (Fig. 1)

Ball Joint (Fig. 2)

0W40

Gearcase Lube

Fluid

FGrease Grease fittings (3 pumps

"LGrease

Add to proper level on dipstick.

lines. See page 36.

See page 78.

See page 77.

maximum).

Locate fitting on back side of struts and grease with grease gun.

(Fig. 1)

(Fig. 2)

MAINTENANCE AND LUBRICATION

Premium 4 Synthetic Lubricant

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

NOTE: See page 114 for the part numbers of Polaris products.

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

Although Polaris Premium 4 is the only oil recommended for use in this engine, use of any API certified SH oil is allowable as long as it’s 0W-40. Oil may need to be changed more frequently if Polaris Premium 4 is not used. Follow the manufacturer’s recommendations for ambient temperature operation.

CAUTION

MAINTENANCE AND LUBRICATION

Oil Check

The dipstick/oil fill (1) is located on the engine on the left side of the ATV. Do not start the engine before the oil check.

NOTE: A rising oil level between checks in cool weather driving can

indicate contaminants such as gas or moisture collecting in the crankcase. If the oil level is over the full/safe mark, change the oil immediately.

1. Position the vehicle on a level surface.

2. Remove the dipstick and wipe it dry with a clean cloth.

NOTE: Lift the lever lock (2) to remove

the dipstick.

3. Reinstall the dipstick completely, but do not lock it. The dipstick must be completely seated.

4. Remove the dipstick and check the oil level. Maintain the oil level between the SAFE

and ADD marks (3). Do not overfill.

NOTE: Due to the dipstick

entry angle into the crankcase, the oil level will read higher on the bottom side of the dipstick. Always read the level on the upper surface (4) of the dipstick.

5. After reinstalling the dipstick, seat the lever lock.

SAFE

ADD 8 OZ

MAINTENANCE AND LUBRICATION

Oil and Filter Change

Change the oil and filter at the intervals outlined in the P eriodic Maintenance Chart beginning on page 69. Always install a new filter when changing the oil.

1. Position the vehicle on a level surface.

2. Run t he engine for two to three minutes until warm. Stop the engine.

3. Clean the area around the drain plug.

4. Place a drain pan beneath engine crankcase and remove the drain plug.

CAUTION

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

5. Allow the oil to drain completely.

6. Replace the sealing washer on the drain plug.

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

7. Reinstall the drain plug and torque to 20 ft. lbs. (27 Nm).

8. Place shop towels beneath the oil filter. Using an oil filter wrench,

9. Using a clean dry cloth, clean the filter sealing surface on the

10. Lubricate t he o-ring on the new filter with a film of fresh engine

11. Install the new filter and turn by hand until the filter gasket

12. Remove the dipstick and fill the sump with two quarts (1.9 l) of

13. Place the gear selector in PARK and set the parking brake.

14. Start the engine and let it idle for one to two minutes. Stop the

15. Re-check the oil level on the dipstick and add oil as necessary to

16. Dispose of used filter and oil properly.

clean and free of burrs, nicks or scratches.

turn the filter counterclockwise to remove.

crankcase.

oil. Check to make sure the o-ring is in good condition.

contacts the sealing surface, then turn and additional 1/2 turn.

recommended oil.

engine and inspect for leaks.

bring the level to the upper mark on the dipstick.

MAINTENANCE AND LUBRICATION

Front Gearcase Oil

Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 66. Maintain the oil level even with the bottom of the fill hole threads (1). Refer to the Gearcase Specifications Chart on page 80 for recommended l ubricants, capacities and torque specifications. Use of other oils may result in improper operation of components. See page 114 for the part numbers of Polaris products.

Oil Check

1. Position the vehicle on a level surface.

2. Remove the fill plug (2) and view the oil level.

3. Add the recommended gearcase oil as needed to bring the level to the bottom of the fill hole threads.

4. Reinstall the fill plug. Torque to specification.

Oil Change

1. Position the vehicle on a level surface and remove the fill plug.

2. Place a drain pan beneath the gearcase, remove the gearcase drain plug (3) located on the bottom right-hand side, and drain the oil.

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

4. Add the recommended fl

5. Reinstall the fill plug. Torque to specification.

6. Check for leaks.

uid.

MAINTENANCE AND LUBRICATION

Transmission Oil

Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 69. Maintain the transmission oil level at the bottom of the fill plug hole (1). Refer to the Gearcase Specifications Chart on page 80 for recommended lubricants, capacities and torque specifications. See page 114 for the part numbers of Polaris products.

The transmission oil fill plug (2) is located on the right side of the ATV behind the footwell. The transmission drain plug (3), is located on the bottom left-hand side of the gearcase.

Oil Check

1. Remove the footwell (see page 86).

2. Remove the fill plug and check the oil level.

3. Reinstall the fill plug. Torque to specification.

4. Reinstall the footwell.

Oil Change

1. Remove the footwell (see page 86).

2. Remove the drain plug and drain the oil into a drain pan. Dispose of properly.

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

4. Remove the fill plug and add the recommended fluid.

5. Reinstall the fill plug. Torque to specification.

6. Check for leaks.

7. Reinstall the footwell.

MAINTENANCE AND LUBRICATION

Rear Gearcase Oil

The rear gearcase has two fill plugs. The rear fill plug is located on the rear of the gearcase and is not easily accessible. The side fill plug (1) is located on the left side of the gearcase. Use the side fill plug when checking or changing oil.

Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 69. Maintain the oil level (2) even with the bottom of the side fill hole. Refer to the Gearcase Specifications Chart on page 80 for recommended lubricants, capacities and torque specifications. See page 114 for the part numbers of Polaris products.

Oil Check

1. Position the vehicle on a level surface.

2. Remove the side fill plug and view the oil level through the fill plug hole.

3. Add the recommended gearcase oil as needed.

4. Reinstall the fill plug. Torque to specification.

Oil Change

1. Place a drain pan beneath the drain and remove the drain plug. Catch and discard used oil properly.

2. Clean and reinstall the drain plug with a new sealing washer. Torque to specification.

3. Remove the side fill plug and add the recommended fluid.

4. Check the oil level. Maintain the oil level at the bottom of the fill plug hole.

5. Reinstall the fill plug. Torque to specification.

6. Check for leaks.

MAINTENANCE AND LUBRICATION

Gearcase Specification Chart

Gearcase Lubricant Capacity Fill Plug

Main Gearcase

(Transmission)

Front Gearcase Premium Demand

Rear Gearcase Premium ATV Angle

Premium AGL

Synthetic Gearcase

Lube

Drive Hub Fluid

Drive Fluid

15.2 oz. (450 ml)

5oz.

(150 ml)

10 oz.

(300 ml)

Torque

14 ft. lbs.

(19.4 Nm)

8-10 ft. lbs.

(11-13.6 Nm)

Side plug 16 ft. lbs.

(21.7 Nm)

Drain Plug

Torque

14 ft. lbs.

(19.4 Nm)

11 ft. lbs.

(15 Nm)

14 ft. lbs.

(19.4 Nm)

Engine Cooling System

Radiator Coolant Level

To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added. Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. Polaris P remium 60/40 is already premixed and ready to use. Do not dilute with water. See page 114 for the part numbers of Polaris products.

NOTE: Always follow the manufacturer’s mixing recommendations

for the freeze protection required in your area.

Any time the cooling system has been drained for maintenance or repair, replace the coolant. If the recovery bottle has run dry, the l evel in the radiator should be inspected. Add coolant as needed.

WARNING

Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the pressure cap.

MAINTENANCE AND LUBRICATION

Engine Cooling System

Radiator Coolant Level

1. Remove the bolts securing the front rack. See illustration.

2. Remove the rack.

3. Remove the pressure cap (1).

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

5. Reinstall the pressure cap.

6. Reinstall the front rack.

NOTE: Use of a non-standard pressure cap will not allow the

recovery system to function properly. Contact your dealer for the correct replacement part.

MAINTENANCE AND LUBRICATION

Engine Cooling System

Coolant Level

The recovery bottle (1) is located on the left side of the machine. To access the recovery bottle, remove the left side panel as outlined on page 86.

Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool). Add coolant as needed.

Cooling System Operation

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

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

NOTE: Some coolant level drop on new machines is normal, as the

system is purging itself of trapped air. Observe coolant levels and maintain as recommended by adding coolant to the recovery bottle.

MAINTENANCE AND LUBRICATION

Steering Assembly

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

Toe Alignment

WARNING

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

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

1. Set the handlebars in a straight-ahead position.

NOTE: Thesteeringfrogcan

be used as an indicator of whether the handlebars are straight. The frog should always point straight back from the steering post.

2. Place stands (1) in front of the vehicle, perpendicular to the rear tires. See illustration.

3. Tie an elastic string around the stands, making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in front of the vehicle (2).

4. Measure the distance from

the string to the rim at the front and rear of the front rim (3). Rear measurement should be 1/16″ -1/8″ (1.5-3 mm) more than the front measurement.

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

for service.

MAINTENANCE AND LUBRICATION

Brakes

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

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

WARNING

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

1. Always keep brake fluid at an adequate level (see page 36).

WARNING

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

NOTE: Under normal operation, the diaphragm extends into the

reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced. Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation. Use Polaris DOT 3 brake fluid. Do not overfill.

MAINTENANCE AND LUBRICATION

Brakes

2. Check the brake system for fluid leaks.

3. Check the brakes for excessive travel or spongy feel.

4. Check the friction pads for wear, damage and looseness.

5. Check the security and surface condition of the disc.

NOTE: Pads should be changed

when worn to 3/64″ (.1 cm).

3/64″ (.1 cm)

Auxiliary Brake

The auxiliary brake system is intended to be used as a backup for the main brake system. Should the main system fail, the rear brake can be activated by depressing the foot pedal on the inside of the right footrest. The hydraulic auxiliary brake system requires no adjustment.

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

the all-wheel single lever system.

MAINTENANCE AND LUBRICATION

Side Panel Removal

1. Remove the seat.

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

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

4. Reinstall the side panel by reversing the removal procedure.

Footwell Removal

1. Remove the four screws (1) on the bottom of the footwell.

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

3. Use a phillips screwdriver andwrenchtoremovethe mudflap screws (3).

4. Remove the footwell.

MAINTENANCE AND LUBRICATION

WARNING

Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death.

Maintain proper tire pressure as described on the decal on your ATV and in the owner’s manual.

Always use original equipment size and type when replacing tires. Make sure the wheels are installed properly. Always replace tires when the tread depth measures 1/8″ (3 mm)

or less.

Tire Tread Depth

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

Front Wheel Hub Tightening

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

1/8I (3 mm)

Wheel Removal

1. Stop the engine, place the transmission in PARK and l ock the parking brake.

2. Loosen the wheel nuts slightly.

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

4. Remove the wheel nuts and remove the wheel.

MAINTENANCE AND LUBRICATION

Wheel Installation

1. Place the transmission in PARK and lock the parking brake.

WARNING

Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death. Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your Polaris dealer.

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

3. Install the wheel nuts and finger tighten.

4. Lower the vehicle to the ground.

5. Torque the wheel nuts to specification.

Wheel Nut Torque Specifications

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

Item Specification

Front Wheel Nuts 27 ft. lbs. (37 Nm)

Rear Wheel Nuts 27 ft. lbs. (37 Nm)

MAINTENANCE AND LUBRICATION

Filter Systems

Air Filter Service

1. Remove the seat, release the air box cover clips, and remove the air box cover.

2. Loosen the clamp and remove the filter.

3. Remove the fabric type pre-filter (1) from the main filter (2). Wash the pre-filter in soapy water, then rinse and let dry.

4. Reinstall the pre-filter over the main filter. (Replace the main filter if needed.)

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

6. Reinstall the air box cover and the seat.

Breather Filter/Hose

1. To access the breather filter (3), remove the left side panel as outlined on page 86. The breather filter is on the hose that runs between the engine and air box.

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

NOTE: It’s not necessary to remove the lower hose from the engine.

3. Inspect the filter for debris. Blow gently through the filter in the direction of the arrow to check for clogging. Replace if needed.

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

5. Reinstall the filter and secure the clamps.

NOTE: The filter is effective with the arrow pointing in either

direction.

CAUTION

Operation of your vehicle without a breather filter can cause engine damage. Always reinstall the breather filter after removing for service.

MAINTENANCE AND LUBRICATION

Lights

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

WARNING

Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation. Wash the headlights frequently to maintain lighting quality.

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

Headlight Lamp Replacement

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

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

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

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

5. Unplug the headlamp from the wiring harness. Be sure to pull on the connector, not on the wiring.

6. Turn the lamp counterclockwise to remove it.

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

NOTE: Make sure the tab on the lamp locates properly in the

8. Reassemble the pod.

housing.

MAINTENANCE AND LUBRICATION

Lights

High Beam Adjustment

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

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

2. Measure the distance from t he floor to the center of the headlight and make a mark on the wall at the same height.

3. Start the engine and turn the headlight switch to high beam.

4. Observe the headlight aim on the wall. The most intense part of the headlight beam should be two inches (5.1 cm) below the mark on the wall.

NOTE: Include rider weight on the seat when measuring.

5. The adjustment knob is located on the right side of the headlight pod. Adjust the beam to the desired position by turning the knob either clockwise or counterclockwise.

Low Beam Adjustment

The low beam can be adjusted slightly upward or downward.

1. Loosen the headlamp mounting bolt (1).

2. Tilt the headlamp upward or downward.

3. Tighten the bolt.

MAINTENANCE AND LUBRICATION

Lights

Headlight Hous in g 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.

NOTE: The distance from the

headlamp parting line to the end of the adjustment knob stop is 5 1/8″ (13 cm).

10. Adjust the headlight aim by turning the adjusting knob.

51/8″ (13 cm)

MAINTENANCE AND LUBRICATION

Lights

Lower Headlamp Removal / Installatio n

1. Turn the back of the headlight harness (1) in a clockwise direction.

2. Pull the harness assembly out from the headlight assembly.

3. Remove the headlamp and install the new headlamp.

4. Install the new headlamp and harness assembly into the headlight assembly. Turn the headlight harness counterclockwise to s ecure.

Taillig ht/Brakelight Lamp Replacement

1. Remove the taillight lens cover mounting screws (1).

2. Remove the lens cover (2) and gasket.

3. Remove the lamp (3).

4. Apply dielectric grease to the socket and install the new lamp.

5. Test the taillight/brakelight.

6. Reinstall the gasket and lens cover.

MAINTENANCE AND LUBRICATION

Spark Plugs

Always use the spark plugs recommended for your ATV. Refer to the specifications section beginning on page 112 for the recommended spark plug type and gap.

CAUTION

Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs.

Spark plug condition is i ndicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color.

WARNING

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

1. Normal

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

NOTE: The tip should not be white. A white insulator tip indicates

overheating, caused by use of an improper spark plug or incorrect carburetion adjustments.

2. Wet Fouled

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

Spark Plug Removal and Replacement

1. Remove the spark plug cap.

2. Using the special wrench provided in the tool pouch, rotate the spark plug counterclockwise to remove.

3. Reverse the procedure for spark plug installation, using the recommended spark plug. Torque to 18 ft. lbs. (24 Nm).

MAINTENANCE AND LUBRICATION

Vehicle Immersion

CAUTION

If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine.

If it’s impossible to take your ATV to a dealer before starting it, follow the steps outlined below.

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

2. Check the air box for any water and dry it if water is present. Filter replacement is required if water intrusion is evident.

3. Turn the fuel valve off.

4. Remove the spark plug.

5. Loosen the carburetor drain screw (1).

6. Turn the engine over several times using the electric start.

7. Dry the spark plug and reinstall, or replace it with a new plug.

8. Tighten the carburetor drain screw.

9. Turn the fuel valve on.

10. Attempt to start the engine. If necessary, repeat the drying procedure.

11. Take the ATV to your dealer for service as soon as possible, whether you succeed in starting it or not.

NOTE: If water has been ingested into the PVT, follow the procedure

on page 99 for drying out the PVT .

MAINTENANCE AND LUBRICATION

Recoil Housing

To prevent possible engine damage, always drain the recoil housing (1) after operating the ATV in very wet conditions. This should also be done before storing the ATV.

Water will enter the recoil housing if the starter handle is disengaged from the rope guide when under water.

The drain screw is located at the bottom of the recoil housing. Use a wrench to remove the screw. Be sure to reinstall the screw after draining the housing.

NOTE: Do not open the crankcase drain unless the engine has

ingested water. On 4-cycle engines, some engine oil will be lost if the crankcase drain is opened.

MAINTENANCE AND LUBRICATION

Spark Arrestor

WARNING

Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death.

Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000° F. Allow components to cool sufficiently before proceeding.

Remove any combustible materials from the area. Wear eye protection and leather work gloves. Do not stand behind or in front of the vehicle while purging. Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas.

Never go under the vehicle while it’s inclined.

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

2. Place the transmission in PARK and start the engine.

3. Purge carbon from the system by momentarily revving the engine several times.

4. If carbon is expelled, cover or plug the exhaust outlet (2) and rap on the pipe around the cleanout plug while revving the engine several more times.

5. If particles are still suspected to be in the muffler, elevate the rear of the vehicle one foot higher than the front. Set the parking brake and block the wheels. Make sure the vehicle is in PARK and repeat steps 3 and 4 until no more particles are expelled when the engine is revved.

6. Stop the engine and allow the arrestor to cool. Reinstall the arrestor plug and remove the outlet cover or plug.

Polaris Sprotsman MV7 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual