Polaris Trail Blazer 2004 Owner's Manual

A card containing important A TV 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.

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Copyright 2003 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.

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 Victory motorcycles S RANGER utility vehicles

Polaris Professional Series Workmobilest

S Utility Task Vehiclest (UTVs) S Personal Task Vehiclest (PTVs) S All-Surface Loaders (ASLs)

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 Service Dealer (MSD) Technician.

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

We also take great pride in our 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, Polaris The Way Out, and Workmobiles are registered trademarks of Polaris Industries Inc.

TABLE OF CONTENTS

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

VEHICLE IDENTIFICATION NUMBERS 6........

SAFETY 7...................................

FEATURES AND CONTROLS 36...............

OPERATION 48..............................

EMISSION CONTROL SYSTEMS 67............

MAINTENANCE AND LUBRICATION 68.........

SPECIFICATIONS 107........................

POLARIS PRODUCTS 110.....................

TROUBLESHOOTING 111.....................

WARRANTY 115..............................

INDEX 118...................................

VEHICLE IDENTIFICATION NUMBERS

The vehicle frame vehicle identification number (VIN)(1) and engine serial number are important for model i dentification when registering your vehicle, when obtaining insurance, and when ordering replacement parts. If your vehicle is stolen, these numbers are essential to the recovery and identification of your vehicle.

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. If both keys are lost, the ignition switch must be replaced. See your Polaris dealer .

NOTE: Record your vehicle’s ID numbers and key number (2) in the spaces provided.

31XX

Frame VIN:

Engine Serial Number (right front side of engine crankcase):

Vehicle Model Number:

Key Number:

SAFETY

Operator Safety

Age Restrictions

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

Know Y our 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 T raining

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 i nformation 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 this vehicle 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 thoroughly inspected at specific intervals.

WARNING

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

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

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

SAFETY

Operator Safety

The following signal words and symbols appear throughout this manual and on your ATV. 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 ATV or in this manual, alerts you to the potential for personal injury.

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

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

CAUTION

NOTE

A note will alert you to important information or instructions.

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

CAUTION

WARNING

SAFETY

Operator Safety

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 ATV 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 t he 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 t errain. Be alert to changing terrain conditions.

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

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

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.

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 ascend a hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make s udden 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 to 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 your 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.

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

prevent unauthorized use or accidental starting.

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

POTENTIAL HAZARD

Operating this ATV without proper instruction.

WHAT CAN

HAPPEN

The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain.

HOW TO AVOID THE

HAZARD

Beginning and inexperienced operators should complete the 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.

POTENTIAL

HAZARD

Failure to follow the age recommendations for this ATV.

WHAT CAN

HAPPEN

Severe injury and/or death could occur if a child under the minimum age recommendation operates an A TV.

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

HOW TO AVOID THE

HAZARD

No one under the age of 16 should operate a Polaris A TV.

WARNING

SAFETY

Operator Safety

POTENTIAL HAZARD

Carrying a passenger on an A TV.

WHAT CAN

HAPPEN

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

HOW TO AVOID THE

HAZARD

Never carry a passenger. The purpose of the long seat is to allow the operator to shift position as needed during operation. It is not intended for carrying passengers.

WARNING

SAFETY

Operator Safety

POTENTIAL HAZARD

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

WHAT CAN

HAPPEN

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

HOW TO AVOID THE

HAZARD

Avoid operating the A TV on pavement. If it’s unavoidable, travel slowly and avoid sudden turns or stops.

WARNING

SAFETY

Operator Safety

POTENTIAL HAZARD

Operating this ATV on public streets, roads or highways.

WHAT CAN

HAPPEN

The ATV could collide with another vehicle.

HOW TO AVOID THE

HAZARD

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

WARNING

SAFETY

Operator Safety

POTENTIAL HAZARD

Operating this ATV without wearing an approved helmet, eye protection and protective clothing.

WHAT CAN

HAPPEN

Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident.

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

HOW TO AVOID THE

HAZARD

Always wear an approved helmet that fits properly.

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

WARNING

SAFETY

Operator Safety

POTENTIAL HAZARD

Operating the ATV after consuming alcohol or drugs.

WHAT CAN

HAPPEN

Consumption of alcohol and/or drugs could seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected.

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

HOW TO AVOID THE

HAZARD

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

POTENTIAL

HAZARD

Operating the ATV at excessive speeds.

WHAT CAN

HAPPEN

Excessive speed increases the operator’s chance of losing control of the ATV, which can result in an accident.

HOW TO AVOID THE

HAZARD

Always operate the ATV at a speed that’s proper for the terrain, visibility and operating conditions, and your experience.

WARNING

SAFETY

Operator Safety

POTENTIAL HAZARD

Attempting wheelies, jumps and other stunts.

WHAT CAN

HAPPEN

Attempting stunts increases the chance of an accident, including an overturn.

HOW TO AVOID THE

HAZARD

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

WARNING

SAFETY

Operator Safety

POTENTIAL HAZARD

Failure to inspect the ATV before operating.

Failure to properly maintain the ATV.

WHAT CAN

HAPPEN

Poor maintenance increases the possibility of an accident or equipment damage.

HOW TO AVOID THE

HAZARD

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

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

POTENTIAL

HAZARD

Removing hands from the handlebars or feet from the footrests during operation.

WHAT CAN

HAPPEN

Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV.

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

HOW TO AVOID THE

HAZARD

Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation.

WARNING

SAFETY

Operator Safety

POTENTIAL HAZARD

Failure to use extra caution when operating the ATV on unfamiliar terrain.

WHAT CAN

HAPPEN

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

HOW TO AVOID THE

HAZARD

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

WARNING

SAFETY

Operator Safety

POTENTIAL HAZARD

Failure to use extra caution when operating on excessively rough, slippery or loose terrain.

WHAT CAN

HAPPEN

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

HOW TO AVOID THE

HAZARD

Do not operate on excessively rough, slippery or loose terrain until you’ve learned and practiced the skills necessary to control the ATV on such terrain.

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

WARNING

SAFETY

Operator Safety

POTENTIAL HAZARD

Turning improperly.

WHAT CAN

HAPPEN

Improper turns could cause loss of control and lead to a collision or overturn.

HOW TO AVOID THE

HAZARD

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

Practice turning at slow speeds before attempting to turn at faster speeds.

Never turn at excessive speed.

POTENTIAL

HAZARD

Operating on excessively steep hills.

WHAT CAN

HAPPEN

The vehicle may overturn.

HOW TO AVOID THE

HAZARD

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

Practice on smaller hills before attempting large hills.

WARNING

SAFETY

Operator Safety

POTENTIAL HAZARD

Climbing hills improperly.

WHAT CAN

HAPPEN

Improper hill climbing could cause loss of control or overturn.

HOW TO AVOID THE

HAZARD

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

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.

WARNING

SAFETY

Operator Safety

POTENTIAL HAZARD

Traveling downhill improperly.

WHAT CAN

HAPPEN

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

HOW TO AVOID THE

HAZARD

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

58.

Always check the terrain carefully before you 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.

WARNING

SAFETY

Operator Safety

POTENTIAL HAZARD

Improperly crossing hills and turning on hills.

WHAT CAN

HAPPEN

Improperly crossing or turning as hills could cause loss of control or overturn.

HOW TO AVOID THE

HAZARD

Never attempt to turn the ATV around on any hill until you’ve mastered the turning technique (on level ground) as described in the owner’s manual. See page 59. Use extra caution when turning on any hill.

Avoid crossing the side of a steep hill.

When crossing the side of a

hill:

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

Avoid hills with excessively slippery or loose surfaces.

Shift your weight to the uphill side of the ATV.

WARNING

SAFETY

Operator Safety

POTENTIAL HAZARD

Stalling, rolling backwards or improperly dismounting while climbing a hill.

WHAT CAN

HAPPEN

The vehicle could overturn.

HOW TO AVOID

THE

HAZARD

Maintain steady speed when climbing a hill.

If all forward speed is

lost:

Keep your weight uphill.

Apply the single lever brake gradually.

When fully stopped, apply the auxiliary rear brake as well, then lock the parking brake.

If the ATV begins rolling

backwards:

Keep weight uphill.

Never apply engine power.

Never apply the auxiliary rear brake while rolling backwards.

Apply the single-lever brake gradually.

When fully stopped, apply the auxiliary 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 59.

WARNING

SAFETY

Operator Safety

POTENTIAL HAZARD

Improperly operating over obstacles.

WHAT CAN

HAPPEN

Operating over obstacles could cause loss of control or overturn.

HOW TO AVOID THE

HAZARD

Before operating in a new area, check for obstacles.

Avoid operating over large obstacles such as rocks and fallen trees when possible. If unavoidable, use extreme caution and always follow proper procedures as outlined in the owner’s manual.

POTENTIAL

HAZARD

Skidding or sliding.

WHAT CAN

HAPPEN

Skidding or sliding can cause loss of control.

If the tires regain traction unexpectedly , the ATV could overturn.

HOW TO AVOID THE

HAZARD

On slippery surfaces such as ice, travel slowly and use extra caution to reduce the chance of skidding or sliding out of control.

WARNING

SAFETY

Operator Safety

POTENTIAL HAZARD

Operating the ATV through deep or fast-flowing water.

WHAT CAN

HAPPEN

Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn.

HOW TO AVOID THE

HAZARD

Avoid operating the A TV through deep or fast-flowing water. If it’s unavoidable to enter water that exceeds the recommended maximum depth (see page 60), 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.

POTENTIAL

HAZARD

Improperly operating in reverse.

WHAT CAN

HAPPEN

The ATV could collide with an obstacle or person, resulting in severe injury.

HOW TO AVOID THE

HAZARD

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

WARNING

SAFETY

Operator Safety

POTENTIAL HAZARD

Operating this ATV with improper tires, or with improper or uneven tire pressure.

WHAT CAN

HAPPEN

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

HOW TO AVOID THE

HAZARD

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

Always maintain proper tire pressure specified for the A TV.

POTENTIAL

HAZARD

Operating the ATV with improper modifications.

WHAT CAN

HAPPEN

Improper installation of accessories or modification of the ATV may cause changes in handling which could lead to an accident.

HOW TO AVOID THE

HAZARD

Never modify the ATV through improper installation or use of accessories. All parts and accessories added to the vehicle must be genuine Polaris Industries Inc. or equivalent components designed for use on this ATV and should be installed and used according to approved instructions. See your authorized Polaris ATV dealer for more information.

WARNING

SAFETY

Operator Safety

POTENTIAL HAZARD

Overloading the ATV or carrying/towing cargo improperly.

WHAT CAN

HAPPEN

Overloading and towing can cause changes in vehicle handling, which could lead to loss of control or an accident.

HOW TO AVOID THE

HAZARD

Never exceed the stated load capacity for this ATV.

Cargo should be properly distributed and securely attached.

Reduce speed when carrying cargo or pulling a trailer. Allow a greater distance for braking.

Always follow the instructions in the owner’s manual for carrying cargo or pulling a trailer. See page 64.

POTENTIAL

HAZARD

Operating on frozen bodies of water.

WHAT CAN

HAPPEN

Severe injury or death can result if the ATV and/or the operator fall through the ice.

HOW TO AVOID THE

HAZARD

Never operate the ATV on a frozen body of water. If you’re confident that the ice is thick enough and sound enough to support the machine and its operator, as well as the force created by a moving vehicle, exercise extreme caution.

WARNING

SAFETY

Operator Safety

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.

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

Always keep combustible materials away from the exhaust system. Exposure to the hot components could result in a fire.

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

SAFETY

Safety Decals and Locations

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

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

DNever operate this vehicle on HILLS steeper than 25 degrees

T o prevent flipover on hilly terrain, when going up or down, use throttle and brakes gradually .

DREVERSE operation can be dangerous, evenat lowspeeds. Steering be-

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

DUse OVERRIDE for reverse speed limiter with caution. To prevent loss

of control, never activate override button with open throttle.

DPA RKING BRAKE may relax when used for more than 5 minutes. When

parking on grades, leave shift in forward.

WARNING

7079085

25°

S Moving parts hazard under belt- clutc h guard. To

prevent s erious injury, do not operate vehicle with guard remov ed.

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

7078689

WARNING

7077920

WARNING

SAFETY

Safety Decals and Locations

WARNING

Improper A TV use can result in SEVERE INJUR Y or DEA TH

ALWAYS USE

AN APPROVED

HELMET AND PROTECTIVE

GEAR

NEVER USE

ON PUBLIC

ROADS

NEVER CARRY

PASSENGERS

NEVER USE WITH DRUGS OR ALCOHOL

NEVER operate:

ALWAYS:

SAFETY

Safety Decals and Locations

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.

WARNING

7078253

Chain Freeplay Is Important. Adjust Freeplay to 3/16″ -3/8″ DO NOT Overtension. See Owner’s Manual.

Torque Nut on Eccentric Bol ts: To 30 Ft. Lbs. (For models without a hitch). To 40 Ft. Lbs. (For models with ahitch).

7078572

MANUFACTURED BY: POLARIS IND. INC.

DATE:

VIN:

THIS VEHICLE IS AN ALL TERRAIN VEHICLEAND IS NOT INTENDED FOR USE ON PUBLIC ROADS.

7171492

CE VÉHICULE EST UN VÉHICULE TOUT TERRAIN QUI NiEST PAS DESTINÉ À ÊTRE UTILISÉ SUR LES CHEMINS PUBLICS.

Canadian Certification Decal

Reverse Speed is limited.

Reverse override is controlled by the override switch.

See your Owner’s Manual.

OVERRIDE

SWITCH

7079906

Under Seat

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 S tandards 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 t he best protection for your eyes. They should be kept clean and be of shatterproof design (bearing the 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.

FEATURES AND CONTROLS

Electrical Switches

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.

WARNING

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

Main Switch (2) - To start the engine, slide the stop switch to the center RUN position and turn the main key switch clockwise past the ON position. Release the key when the engine starts. NOTE: Turning off the main switch will shut off all electrical power to the vehicle, including the lights.

Engine Stop Switch (3) - The engine will not start or run when the switch is in its OFF position. Its purpose is to provide the operator with a quick means of engine shutdown in case of an emergency. To stop the engine, slide the stop switch either right or left to the OFF position. NOTE: Turning off the engine stop switch will shut off all electrical power to the vehicle, including the lights.

RUN

OFFOFF

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

FEATURES AND CONTROLS

Throttle Lever

Engine speed and vehicle movement are controlled by pressing the throttle lever. The throttle lever (1) 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.

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.

WARNING

Do not start or operate an ATV with sticking or improperly operating throttle controls, which could cause an accident and lead to severe injury or death.

Always contact your dealer for service repairs 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.

WARNING

FEATURES AND CONTROLS

Light Switches

The light switch is located on the left handlebar (1). It’ s used to turn the lights on and off. NOTE: The lights won’t work unless the key is in the ON position and the shut-off switch is in the RUN position.

Indicator Lights

With the engine running, verify the function of all indicator lights each time the ATV is used.

NOTE: The taillight is on whenever the main switch (key) is on. Turn the key off to prevent battery drain.

1. Transmission Neutral Indicator

2. Transmission Reverse Ind icator

3. Oil Warning (indicates a low oil level.

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.

WARNING

FEATURES AND CONTROLS

Brakes

Check the brake fluid level in the master cylinder before each use of the ATV. The master cylinder (1) is located on the left handlebar.

1. Position the ATV on level ground with the handlebars straight.

2. View the fluid level through the 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: 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. We recommend the use of Polaris DOT 3 brake fluid. Do not overfill.

3. If the fluid level is low, add DOT 3 brake fluid only. See page 110 for the part numbers of Polaris products.

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

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.

WARNING

FEATURES AND CONTROLS

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.

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.

WARNING

FEATURES AND CONTROLS

Parking Brake

Setting the Parking Brake

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

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

3. 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 may 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.

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.

WARNING

FEATURES AND CONTROLS

Auxiliary Brake

The auxiliary brake (1), is 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.

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

Aggressively applying the rear 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.

WARNING

FEATURES AND CONTROLS

Choke

The choke assists in starting a cold engine. Refer to the engine starting procedure on page 51 for correct choke and throttle settings during starting.

Fuel Valve

The fuel valve (1) is located on the left side of the vehicle, below the fender. It has three positions:

OFF: For vehicle storage and when transporting.

ON: For normal operation.

RES: For reserve supply if m ain supply is exhausted.

NOTE: There’s about a 7 to 10 mile (11.2 to 16 km) range on reserve gas. Always refill the gas tank as soon as possible after using the reserve supply.

Always return valve to ON position after refueling.

Fuel Tank

The fuel tank filler cap (2) is located directly below the handlebar. Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. Refer to the specifications section beginning on page 107 for capacities.

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.

FEATURES AND CONTROLS

Fuel Safety

Gasoline is highly flammable and explosive under certain conditions.

S Always exercise extreme caution whenever handling gaso-

line.

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.

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.

WARNING

FEATURES AND CONTROLS

Oil Injection Tank

The oil injection tank filler cap (1) is located on the front of the vehicle. Refer to the specifications section beginning on page 107 for capacities.

Mixing brands or using a non-recommended oil may cause serious engine damage. We recommend the use of Polaris Premium Synthetic 2-cycle oil for your 2-cycle Polaris ATV. Never substitute or mix oil brands.

To avoid serious engine damage, always top off the oil level when refueling.

CAUTION

FEATURES AND CONTROLS

Automatic Transmission Gear Selector

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

F: Forward

N: Neutral

R: Reverse

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

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.

CAUTION

FEATURES AND CONTROLS

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 41).

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 51.

4. Reach under the side panel and grasp the 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, then pull the rope abruptly and forcefully to start the engine.

6. Repeat steps 4-5 if necessary.

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.

CAUTION

OPERATION

Break-In Period

The break-in period for your new P olaris ATV is defined as the time it takes t o use the first tank of fuel. 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.

Use of any oils other than those recommended by Polaris may cause serious engine damage. We recommend the use of Polaris 2-cycle oil for your 2-cycle engine.

Lack of proper lubrication will cause serious engine damage. Always fill the oil tank when refueling the ATV.

OPERATION

Break-In Period

The first tank of fuel must be pre-mixed according to the following instructions. After the break-in period, the oil injection system will provide the necessary engine lubrication without pre-mixing.

1. Premix the recommended oil with gasoline in a suitable gas container. Refer to the chart below for ratios.

2. Fill the fuel tank (see page 43), then fill the oil tank with the recommended oil.

3. Drive slowly at first. Vary the throttle positions.

4. Perform regular checks on fluid levels, controls, and areas outlined on the daily pre-ride inspection checklist on page 50.

After the first tank of pre-mixed fuel has been used, verify that the oil level in t he oil tank has dropped, indicating that the oil pump is functioning properly. If the level has not dropped, see your dealer for oil pump bleeding and repeat the pre-mix procedure.

Fuel/Oil Premix Chart

Fuel Oil @ 40:1

Gallons (Liters) Ounces (Liters)

1 (3.8) 3.2 (.09)

5 (18.9) 16 (.47)

10 (37.9) 32 (.95)

OPERATION

Pre-Ride Inspection

Use the following checklist to verify that your vehicle is in proper working condition before each use.

Item/Inspection Procedure

1. Tires - Check condition and pressures.

2. Fuel and oil tanks - Fill both tanks to their proper levels.

3. Fluid levels - Inspect all other fluid levels.

4. All brakes - Check operation, adjustment and fluid level (includes auxiliary brake).

5. Throttle - Check for free operation and closing.

6. Headlight/Taillight/Brakelight - Check operation of all indicator lights and switches.

7. Engine stop switch - Check for proper function.

8. Wheels - Check for tightness of wheel nuts and axle nuts; check that axle nuts are secured by cotter pins.

9. Drive chain - Check condition and slack (refer to drive chain adjustment section); lubricate when needed.

10. Air cleaner element - Check for dirt; clean or replace.

11. Steering - Check for free operation, noting any unusual looseness in any area.

12. Loose parts - Visually inspect vehicle for any damaged components or loose nuts/bolts or fasteners.

13. Ri ding gear - Wear a helmet, goggles and protective clothing.

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.

WARNING

OPERATION

Starting the Engine

Starting a Cold Engine

1. Place the transmission in neutral and lock the parking brake. Make sure the fuel valve is on.

2. Sit on the vehicle and pull the choke knob (1) out until it stops. NOTE: If the knob doesn’t stay where positioned, increase the tension by rotating the tension adjusting nut (2) clockwise.

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.

3. Move the engine stop switch to RUN. NOTE: Do not press the throttle while starting the engine.

4. Turn the ignition key past the ON position to engage the starter for a maximum of five seconds. Release the key when the engine starts. If it doesn’t start, release the key and wait five seconds. Activate the starter for another five seconds. Repeat until the engine starts.

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

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

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.

WARNING

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

CAUTION

OPERATION

Starting the Engine

Starting a Warm Engine

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

1. Position the vehicle on a level surface and place the transmission in neutral.

2. Lock the parking brake, turn the fuel tank valve to 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 (pulled half way out) may be necessary. NOTE: If the engine is over-choked when warm, depress the throttle lever fully while cranking to aid in starting.

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

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

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

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

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 Up hill

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.

If all forward speed is lost:

Keep your weight uphill. Apply the single lever brake, gradually. When fully stopped, apply the

auxiliary brake as well, then lock the park brake.

If the ATV begins rolling backwards:

Keep your weight uphill. Never apply engine power. Never apply the auxiliary rear brake while rolling backwards.

Apply the single-lever brake, gradually. When fully stopped, apply the auxiliary 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 on page 59.

25_ Maximum

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

Sidehilling can be a dangerous type of driving 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!

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.

WARNING

OPERATION

Driving Safely

Driving Do w nhill

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 the brakes slightly to aid in s lowing, using the single brake lever.

NOTE: Familiarize yourself with operation of the auxiliary rear brake pedal for additional braking in the event of normal service brake loss.

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

WARNING

OPERATION

Driving Safely

Turning Around on a Hill

If the vehicle stalls while climbing a hill, never back it down the hill! One maneuver that can be used when it’s necessary to turn around while climbing a hill is the K-turn:

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

2. Leave 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 brake lever, release the parking brake lock and slowly allow the vehicle to roll around to your right until it’s pointing across the hill or slightly downward.

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

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

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

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.

8’

Uphill

OPERATION

Driving Safely

Driving Through Water

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

1. Determine water depths and current before crossing.

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

3. Proceed slowly, avoiding rocks and obstacles 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 68. The following areas need special attention: engine oil, transmission oil, front and rear gearcases and all grease fittings.

OPERATION

Driving Safely

Driving Through Water

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 t ake 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.

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.

CAUTION

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.

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.

WARNING

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.

NOTE: Most Polaris ATVs are 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.

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.

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.

CAUTION

OPERATION

Hauling Cargo

Your ATV has been designed to carry or tow a certain amount of load (if equipped with racks). 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.

2/3

1/3

OPERATION

Hauling Cargo

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 DISTANCE 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 LOADS MUST BE CARRIED 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. When cargo loads are carried high on the racks, the weight of the loads must be reduced to maintain stable operating conditions.

S ALL LOADS MUST BE SECURED BEFORE OPERATING.

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

S OPERATE ONLY WITH STABLE AND SAFELY ARRANGED

LOADS. When handling off-centered loads that cannot be centered, securely fasten 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 CONTRO L

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

S EXTREME CAUTION MUST BE USED when operating with

loads extending over the rack sides. Stability and maneuverability may be adversely affected, causing the machine to overturn.

S DO NOT BLOCK THE FRONT HEADLIGHT BEAM when

carrying loads on the front rack.

S DO NOT 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.

WARNING

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 gear.

3. Set the parking brake.

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

Spark Arrestor

Your Polaris ATV has a spark arrestor that was tested and approved in accordance with the USDA Forestry Service Standard 5100-1C.

Exhaust Emission Control System

The emissions from the exhaust of this vehicle are controlled by engine design, including factory-set carburetion 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 (1) is located on the recoil cover.

MAINTENANCE AND LUBRICATION

Accessories

Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights. Accessory outlets are available for all models. Contact your Polaris dealer for more information.

Polaris has a wide range of additional accessories available for your ATV. See your P olaris dealer.

Periodic Maintenance Schedule

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

Maintenance intervals in the following charts are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use, such as operation in wet or dusty areas, should be i nspected and serviced more frequently.

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 Chart Key

" Perform these operations more often under severe use, such as in

dirty or wet conditions, to purge water or dirt contamination from grease fittings and other critical components.

J Dealer service item.

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Hours of operation are based on a 10 mph average. If service is due at 20 hours, the equivalent odometer reading would be 200 miles. Perform all services at whichever reading is reached first.

Item Hours/

Miles

Frequency Remarks

Brake System Pre-Ride Pre-Ride Inspect

Auxiliary Brake Pre-Ride Pre-Ride Inspect

Tires Pre-Ride Pre-Ride Inspect

Wheels Pre-Ride Pre-Ride Inspect

Frame nuts, bolts, fasteners

Pre-Ride Pre-Ride Inspect

Oil level Pre-Ride Pre-Ride Check when refueling

" Air filter,

Pre-cleaner

Pre-Ride Pre-Ride Inspect; clean

Coolant level Pre-Ride Pre-Ride Replace coolant every two

years

Fuel and oil tanks Pre-Ride Pre-Ride Fill to proper levels

Throttle Pre-Ride Pre-Ride Check operation

Lights Pre-Ride Pre-Ride Check operation

Engine stop switch Pre-Ride Pre-Ride Check operation

Drive chain Pre-Ride Pre-Ride Check condition/slack

Steering Pre-Ride Pre-Ride Check for free operation

" Air box sediment

tube

Pre-Ride Pre-Ride Drain deposits whenever

visible

Headlamp Pre-Ride Pre-Ride Check operation daily; ap-

ply Polaris dielectric grease to connector when replaced

" More often under severe use, such as dirty or wet conditions J Dealer service item

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.

WARNING

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item Hours/

Miles

Frequency Remarks

Taillight/brakelight Pre-Ride Pre-Ride Check operation daily; ap-

ply Polaris dielectric grease to socket when replaced

" Air filter,

main element

Weekly Weekly Inspect; replace as needed

" Transmission oil

level

20 hrs Monthly Inspect monthly; change

annually

Battery 20 hrs Monthly Check terminals; clean;

J Brake pad wear 10 hrs Monthly Inspect periodically

Engine cylinder head and cylinder base fasteners

25 hrs 3 months Inspect (re-torque required

at first service only)

" General lubrication 50 hrs 3 months Lubricate all fittings, pivots,

cables, etc.

Oil Pump Cable 50 hrs. 6 months Inspect, adjust, lubricate,

replace if required

Carburetor float bowl

50 hrs. 6 months Drain bowl periodically and

prior to storage

J Throttle Cable/ETC

Switch

50 hrs. 6 months Inspect; adjust; lubricate;

replace if necessary

Choke (enricher) cable

50 hrs. 6 months Inspect; adjust; lubricate;

replace if necessary

Shift linkage 50 hrs. 6 months Inspect; adjust

J Drive belt 50 hrs. 6 months Inspect; replace as needed

" Steering 50 hrs. 6 months Inspect daily; lubricate

" Front suspension 50 hrs. 6 months Inspect; lubricate; tighten

fasteners

" Rear suspension 50 hrs. 6 months Inspect; tighten fasteners

" Drive chain(s) 50 hrs. 6 months Inspect daily; adjust and lu-

bricate if needed

" Rear axle 50 hrs. 6 months Inspect bearings

" More often under severe use, such as dirty or wet conditions J Dealer service item

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item Hours/

Miles

Frequency Remarks

Spark plug 100 hrs. 12 months Inspect; replace as needed

J Ignition Timing 100 hrs. 12 months Inspect; adjust as needed

J Fuel system 100 hrs. 12 months Check for leaks at tank

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

J Fuel filter 100 hrs. 12 months Replace annually

J Clutches

(drive and driven)

100 hrs. 12 months Inspect; clean

Engine mounts 100 hrs. 12 months Inspect

J Oil filter 100 hrs. 12 months Replace

J Shift selector box 200 hrs. 24 months Change lubricant every two

years

J Brake fluid 200 hrs. 24 months Change every two years

Spark arrestor 300 hrs. 36 months Clean out

J Front and rear

wheel bearings

300 hrs. 36 months Inspect; replace as needed

Idle speed As required Adjust

Recoil housing As required Drain moisture out after rid-

inginwater

J Toe adjustment As required Periodic inspection; adjust

when parts are replaced

Headlight aim As required Adjust as needed

" More often under severe use, such as dirty or wet conditions J Dealer service item

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.

WARNING

MAINTENANCE AND LUBRICATION

Periodic Maintenan ce Record

Use the following chart to record periodic maintenance.

Maintenance

Interval

Performed

Servicing

Date

Servicing

Dealer

or Person

Remarks

10 hrs.

20 hrs.

50 hrs.

100 hrs.

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

NOTE: Hours are based on 10 mph average. If service is due at 20 hours, the equivalent odometer reading would be 200 miles. Perform all services at whichever reading is reached first.

Lubrication Chart Key

" More often under severe use, such as wet or dusty conditions

L Polaris Premium All Season Grease or grease conforming to NLG

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

∆ When suspension action becomes stiff, or after washing

Item Lube Method Frequency

Engine Polaris

Injection Oil

Fill oil tank. See page 45. As needed,

when refueling

Brakes DOT 3 fluid only Maintain level between fill

lines. See page 39.

As required; change every two years or 200 hours

Drive chain(s) O-ring chain lube

or SAE 80/90

Lubricate as often as required. Before each ride in wet conditions

As required

Transmission AGL Synthetic

Gearcase Lube

See Page 76. Check every 6

months/1000 miles. Change annually or at 100 hours

(1) Ball Joint

"L Grease

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

Every 3 months or 50 hours

(2) Swing Arm Bushings

"L Grease

Locate fittings on swing arm and grease with grease gun.

Monthly or at 20 hours

(2)

(1)

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Polaris 2-Cycle Lubricants

Polaris Premium 2-cycle lubricants are the most advanced formulation of oils, specifically designed for today’s 2-cycle engines. These lubricants provide additives for 2-cycle engines that are lacking in today’s fuel. These necessary additives keep ring grooves cleaner for less ring sticking and improved overall engine cleanliness.

With new generation lubricity technology, Polaris oils excel in meeting the lubrication demands of today’s high performance 2-cycle engines. We recommend the use of these optimum oils for Polaris liquid cooled or air cooled 2-cycle engines.

Polaris premium 2-cycle oils will mix with each other, but consistent performance will be enhanced by selecting only one of the premium oils and m aintaining regular use of that oil through the life of the unit. Your dealer will be able to assist you with that selection, based on your operating conditions and riding style.

Never mix Polaris premium 2-cycle oils with any other brand of oil, including Polaris Nature Oil Biodegradable oil. Their incompatibility could result in engine damage. For best performance, we recommend that you choose one oil for your ATV, then continue to use it for the life of the unit.

See page 110 for the part numbers of Polaris products.

Polaris VES II Synthetic 2-Cycle Oil

Your vehicle has been primed with VES II synthetic oil. We recommend the continued use of this oil for your ATV. This lubricant has been specially formulated for low smoke, low odor, low deposits and high lubricity.

Premium 2-Cycle Oil

Polaris also has a TC-W3 premium oil or Premium Gold Synthetic Oil suitable for use in all of our 2-cycle products.

CAUTION

Mixing brands or using a non-recommended oil may cause serious engine damage. We recommend the use of Polaris 2-cycle oils for your 2-cycle engine. Never mix oil brands.

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Engine Oil Check

The oil tank cap (1) is located forward of the headlight. Check the oil before each use of the vehicle. Refill the oil when refueling.

1. Position the ATV on a level surface.

2. Remove the oil tank cap and inspect the oil level in the tank.

3. Add oil as needed to bring the level to the full mark. Do not overfill.

4. Reinstall the oil tank cap.

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Transmission Oil Check

The transmission oil dipstick (1) is located on the right side of the vehicle. Check the transmission oil level monthly or every 1000 miles (1600 km), whichever comes first. Maintain the transmission oil level in the SAFE operating range (2). Change transmission oil annually. We recommend the use of AGL Synthetic Gearcase Lubricant. See page 110 for the part numbers of Polaris products.

1. Position the ATV on a level surface.

2. Remove the transmission oil dipstick and wipe it clean.

3. Reinstall the dipstick, then remove it and read the oil level. If the level is low, add the recommended gearcase oil to bring the level within the safe operating range on the dipstick.

4. Reinstall the dipstick.

Transmission Oil Change

1. Place a drain pan beneath the transmission oil drain plug area.

2. Loosen the jam nut (A).

3. Turn the adjuster bolt (B) in to allow the removal of the drain plug (C).

4. Remove the drain plug and wipe the magnetic end clean to remove accumulated metallic filings.

5. After the oil has drained completely, install a new sealing washer and reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm).

6. Turn the adjuster bolt (B) out until it touches the frame, and then turn an additional 1/2 turn.

7. Tighten the jam nut securely while holding the adjuster bolt.

8. Add the recommended lubricant through the dipstick hole until the oil level is between the upper and lower limits. Do not overfill.

9. Check for leaks.

MAINTENANCE AND LUBRICATION

Adjustments

Oil Pump Bleeding

1. Fill the oil tank with the recommended oil. See page 110 for the part numbers of Polaris products.

2. Loosen the bleeder screw one full turn. Allow oil to flow from the bleed screw for five to ten seconds, then tighten the bleed screw.

3. Start the engine and rotate the oil pump lever (2) to its full open position. With the engine at idle, hold the lever up for thirty seconds to purge all air from the system.

CAUTION

If the oil supply line has been disconnected from the pump, or if the oil reservoir and supply line have been completely run out of oil, the oil pump must be bled. If the pump is not bled, air in the lines may prevent oil delivery to the engine, resulting in severe engine damage.

CAUTION

Allowing the engine to run while the bleed screw is loose will result in loss of oil, which will cause serious engine damage. Always retighten the bleed screw if it’s been loosened for service.

MAINTENANCE AND LUBRICATION

Adjustments

Oil Pump

If it becomes necessary to increase oil flow into the fuel system, the oil pump can be adjusted.

1. Before adjusting the oil pump, check the engine idle RPM and carburetor settings in the specifications section beginning on page 107.

2. Loosen the throttle cable jam nut and turn the adjuster (1) in or out until there is 1/16″ -1/8″ (.16 - .32 cm) of throttle lever travel before the throttle slide starts to open.

3. Place very slight pressure on the throttle lever (2) until all freeplay is removed from the throttle cable (to the point where the carb slide is just starting to rise).

4. Loosen the l ocknut (3). Turn the adjuster in or out until all freeplay is removed from the oil pump cable (the point where the oil pump arm is j ust starting to move off its stop). The pump stop keeps the pump arm from rotating any further down than the idle position so no visual alignment of marks is necessary. Tighten the locknut.

MAINTENANCE AND LUBRICATION

Adjustments

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, such as operation in hilly country or in muddy terrain.

1. Always maintain brake fluid level as recommended (see page 39).

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: Install new brake pads when pads arewornto3/64″ (.1 cm), or about the thickness of a U.S. dime.

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.

3/64″ (.1 cm)

MAINTENANCE AND LUBRICATION

Adjustments

Toe Alignment

Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8″ to 1/4″ toe out.

1. Set the handlebars in a straight-ahead position. NOTE: The steering frog can 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″ (.2to.3cm) more than the front measurement.

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

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.

MAINTENANCE AND LUBRICATION

Adjustments

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.

Camber and Caster

The camber and caster are non-adjustable.

Rear Spring

The rear shock absorber spring is adjusted by rotating the adjuster (1) either clockwise or counterclockwise to increase or decrease spring tension.

NOTE: Accessory springs are available through your Polaris dealer.

MAINTENANCE AND LUBRICATION

Adjustments

Handlebars

The handlebars can be adjusted for rider preference.

1. Remove the handlebar cover and locate handlebar bolts (1).

2. Loosen the four bolts.

3. Adjust the handlebar to the desired height. Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right.

4. Torque the front two bolts to 10-12 ft. lbs. (14-17 Nm), then torque the rear two bolts. A gap of up to 1/8” will remain at the rear bolts.

Throttle Cable Freeplay

Throttle cable freeplay is adjusted at the handlebar.

1. Slide the boots (1) off the inline cable adjuster sleeve (2). Loosen the adjuster locknut (3).

2. Turn the adjuster until 1/16″ to 1/8″ freeplay is achieved at the thumb lever . NOTE: While adjusting freeplay, be sure to flip the throttle lever back and forth.

3. Tighten the locknut and slide the boots over the cable adjuster until they touch at the midpoint of the adjuster.

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

WARNING

MAINTENANCE AND LUBRICATION

Adjustments

Carburetor

IMPORTANT: Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for each 1000-foot (304.8 m) increase in elevation. Although this power cannot be regained, adjustments to the carburetor and drive system can be made to allow more efficient operation. Optional jets, available from your Polaris dealer, are required for operation above 6,000 feet and temperatures below +40 degrees F. (4 degrees C.)

NOTE: Continuous operation of the engine without proper jetting when required can cause poor performance, overheating or engine damage. See your Polaris dealer for more information about jetting t he ATV for conditions in your area.

If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted.

1. Warm up the engine by running the vehicle for approximately five minutes.

2. Place the transmission in gear and lock the parking brake.

3. Adjust the carburetor idle screw (1) either in or out until the desired idle RPM is reached. Turn the screw in (clockwise) to raise RPM. Turn the screw out (counterclockwise) to lower RPM.

The following variations apply to air screw (2) adjustment for 2-cycle engines:

S For improving cold weather start and reducing audible detonation

noise, the air screw can be closed from 1/2 to 1 turn by turning the screw clockwise.

S During hot weather and/or high altitude operation the air screw can

be adjusted for smoother operation by turning the screw counterclockwise for approximately 2 turns.

MAINTENANCE AND LUBRICATION

Adjustments

Wheel Removal

1. Stop the engine, place the transmission in gear and lock 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.

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 your 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 cm) or less.

WARNING

MAINTENANCE AND LUBRICATION

Adjustments

Wheel Installatio n

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

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 according to the wheel nut torque specifications chart.

NOTE: All nuts that have a cotter pin installed must be serviced by an authorized Polaris dealer.

Wheel Nut Torque Specifications

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

Bolt Size Specification

Front 3/8″ 20 ft. lbs. (27 Nm)

Rear 3/8″ 20 ft. lbs. (27 Nm)

Rear 1/2″ 50 ft. lbs. (68 Nm)

MAINTENANCE AND LUBRICATION

Adjustments

Front Wheel Hub Tightening

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

Tire Tread Depth

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

1/8I (.3 cm)

WARNING

Operating the vehicle with worn tires will increase the possibility of skidding, which could lead to loss of control and serious injury or death. Always replace tires when the tread depth measures 1/8″ (.3 cm) or less.

Use of non-standard size or type of tires or improper tire inflation may adversely affect vehicle maneuverability and cause loss of control resulting in serious injury or death. Maintain proper tire pressure as outlined in this owner’s manual. When replacing a tire always use original equipment size and type.

WARNING

MAINTENANCE AND LUBRICATION

Adjustments

Drive Chain

Polaris ATV drive chains are equipped with o-ring-sealed, permanently greased pins and rollers. However, the outer surfaces of the roller must be lubricated.

1. Always inspect the drive chain prior to operating the vehicle. Check for damaged or missing o-rings or damaged rollers.

2. Check for correct slack adjustment.

3. Maintain the stone guard to rear sprocket clearance at 1/8″ (.3 cm).

4. Regularly lubricate the drive chain with Polaris chain lube or S AE 80-90 lube. See page 110 for the part numbers of Polaris products.

Cylinder Head/Cylinder Base Fastener

Have your dealer check the ATV cylinder head and cylinder base fasteners for proper torque at the first service or after 25 hours.

Washing the drive chain with a high pressure washer or gasoline can cause damage to the o-rings, causing premature wear and drive chain failure. Don’t use a high pressure washer or gasoline to clean the drive chain.

CAUTION

MAINTENANCE AND LUBRICATION

Adjustments

Rear Drive Chain Slack

Check the amount of chain slack in three different locations by moving the vehicle slightly forward to gain slack at the top side of the rear chain. Measure the chain slack at the tightest of the three positions. At this point the chain should have 3/16″-3/8″ (.48 cm - .95 cm) deflection. Use the following procedure if adjustment is required.

1. Loosen the chain guide.

2. Loosen the two eccentric locking bolts (1).

3. Loosen the caliper mounting bracket bolt located on the left side of the swing arm.

4. Insert a pin punch (2) through the sprocket hub and into the eccentric housing.

Adjusting or operating the ATV with improper rear drive chain slack can result in severe damage to the transmission and drive components. Always make sure the slack is within the stated specifications.

CAUTION

3/16″-3/8″ (.48 cm - .95 cm)

MAINTENANCE AND LUBRICATION

Adjustments

Rear Drive Chain Slack

1. Roll the ATV forward or backward to adjust the chain slack to the proper tension. See the illustration for proper splice link clip opening position (1).

2. Tighten the eccentric locking bolts to 30 ft. lbs. (41 Nm) for machines without the hitch and 45 ft. lbs. (61 Nm) for machines with a hitch.

3. Tighten the caliper mount bolt to 10-12 ft. l bs. (14-17 Nm).

4. Remove the pin punch.

5. Roll the ATV forward, checking chain tension in several places around the chain. NOTE: The chain is adjusted correctly when the tightest portion of the chain has approximately 3/8” (10mm) deflection.

6. Position the chain guide to allow 1/8” (3mm) clearance and tighten the retaining bolt to 5 ft. lbs. (7 Nm).

7. Reinstall the chain guard if applicable.

MAINTENANCE AND LUBRICATION

Filter Systems

Air Filter Removal and Service

1. Remove the ATV seat.

2. Release the clips securing the cover assembly to the air box.

3. Loosen the clamp securing the filter, and remove the filter.

4. Remove the foam pre-filter from the main filter.

5. Wash the pre-filter in soapy water, then rinse and let dry.

6. Re-install the pre-filter over the main filter. (Replace the main filter if needed.)

Air Filter Installation

1. Check the condition of the air box and replace if necessary .

2. Replace the filter over the carburetor boot. Make sure t he filter is fully seated in the air box.

3. Tighten the clamp. Do not overtighten, as filter damage could occur .

4. Check the cover gasket and replace if needed. B e sure the cover is seated properly, then snap the clips onto the cover.

5. Reinstall the ATV seat.

Air Filter Cleanin g

NOTE: Always replace the main filter when it becomes dirty. In an emergency situation, however, you may clean the main filter if you observe the following practices.

1. Never immerse the main filter in water. Dirt can be transferred to the clean air side of the filter.

2. If compressed air is used for cleaning, never exceed a pressure of 40 PSI. Always use a dispersion-type nozzle to prevent filter damage, and blow the air from the inside to the outside.

NOTE: Replace the air filter every 50 hours and more often when the vehicle is operated in very dirty conditions.

MAINTENANCE AND LUBRICATION

Lights

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

Headlight Lamp Replacement

1. Remove the front cover and unplug the light harness.

2. Remove the rubber cap from the back of the headlight to reveal the retention screw.

3. Remove the small phillips head screw, and carefully remove the bulb from the housing.

4. Apply dielectric grease to the light bulb socket before installing the new bulb. Insert the new bulb into the housing and reinstall the retention screw. Reinstall the rubber cap.

5. Reconnect the light harness and reinstall the cover.

6. Adjust the headlight aim if necessary .

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. Do not service the headlamps until they’ve cooled sufficiently.

MAINTENANCE AND LUBRICATION

Lights

Headlight Adjustment

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

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

3. Start the engine and turn on the headlight.

4. Observe the headlight aim on the wall. The most intense part of the headlight beam should be aimed 8” (20.3 cm) below the mark placed on the wall. NOTE: Include rider weight on the seat when measuring.

5. Adjust the beam to the desired position by turning the adjustment screws (1):

S Turning the right screw clockwise moves the intense spot of light up

andtotheleft.

S Turning the left screw clockwise moves the intense spot of the light

up and to the right.

S Turning the bottom screw clockwise adjusts the light upward.

MAINTENANCE AND LUBRICATION

Lights

Taillight/Brakelight Lamp Replacement

If the taillight/brakelight does not work the lamp may need to be replaced.

1. Remove the taillight lens cover mounting screws. Remove the lens cover and gasket and set aside for reassembly.

2. Remove the lamp (1) and replace it with a new lamp.

3. Test the taillight/brakelight to see that it’s working.

4. Reinstall the gasket and lens cover .

Indicator Lamp Replacement

1. Remove the instrument panel, if necessary, to access the back of the indicator panel.

2. Using a small, straight-blade screwdriver, turn the base of the bulb 1/4 turn counterclockwise.

3. Using a needle-nose plier or similar tool, pull the lamp out of the indicator panel housing.

4. Insert the new bulb and seat it by turning it 1/4 turn clockwise.

5. Reassemble the pod or front cover.

MAINTENANCE AND LUBRICATION

Spark Plugs

Always use t he spark plugs recommended for your ATV. Refer to the specifications section beginning on page 107 for the recommended spark plug type and gap.

Spark plug condition is indicative 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.

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 injection 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. Torque to 14 ft. lbs. (19 Nm).

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

CAUTION

WARNING

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

MAINTENANCE AND LUBRICATION

Vehicle Immersion

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 foot rests.

2. Check the airbox for any water. Drain and dry it if water is present.

3. Turn the fuel valve off.

4. Remove the spark plug.

5. Remove the bowl drain (1).

6. Remove the crankcase drain screw at the left front of the engine bottom.

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

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

9. Reinstall the bowl drain.

10. Reinstall the crankcase drain screw.

11. Turn the fuel valve on.

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

13. 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 t he procedure on page 99 for drying out the PVT.

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.

CAUTION

MAINTENANCE AND LUBRICATION

Spark Arrestor

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

2. Place the transmission in neutral 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 neutral 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.

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.

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.

MAINTENANCE AND LUBRICATION

Recoil Housing

To prevent possible engine damage, always drain the recoil housing (1) after operatingtheATVinverywet 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 recoil handle must be behind the heat shield for it to seal properly.

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.

Polaris Trail Blazer 2004 Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual