Polaris Universal ATV 2000 Owner's Safety And Maintenance Manual

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Page 1

Part No. 9915299 Rev 05

PRINTED IN THE U.S.A.

2000

Universal

ATV

Read this manual carefully. It contains important safety information. This is an

adult vehicle only. Operation is prohibited

for those under 16 years of age.

Owner’s Safety

and

Maintenance Manual

Page 2

WARNING

The engine exhaust from this

product contains chemicals known to cause cancer, birth defects or other reproductive harm.

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FOREWORD

Congratulations and thank you from Polaris Industries Inc. for purchasing one of our all-terrain vehicles (ATV’s). Built with American engineering and manufacturing know-how, it is designed to provide superior riding comfort, enjoyment and safety.

This manual is furnishedto ensure that the operator is aware ofsafe operatingprocedures. It also includes information about the general care and maintenance of yo ur ATV.

Carefully read the following pages. If you have any questions regarding this ATV contact a Polaris dealer for assistance. Remember, Polaris dealers have the knowledge and facilities to provide you with the best service possible.

PROTECT YOUR SPORT

Know all local, state/province riding laws;

Respect your vehicle;

Respect the environment; and

You will gain the respect of others.

We also advise you to strictly follow the recommended maintenance program as outlined. This preventive maintenance program is designed to ensure that allcritical components on this ATV are thoroughly inspected at various intervals.

All information in this manual is based upon the latest product data and specifications available at the time of printing. Polaris Industries Inc. reserves the right to make product changes and improvements which may affect illustrations or explanations.

No part of this manual shall be reproduced or used without the written permission of Polaris Industries Inc.

Illustrations included in this manual are general representations of parts having a similar function. Your model may differ.

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AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An

ATV handles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and driving on hills or over obstacles, if you fail to take proper precautions.

SEVERE INJURY OR DEATH can result if you do not follow these instructions:

• Read this manual and all labels carefully and follow the operating procedures

described.

• Never operate an ATV without proper instruction. Take a training course. Be-

ginnersshouldreceivetrainingfrom a certified instructor. Contact an authorized PolarisATV dealer or call Polaris at 1-800-342-3764tofindout about the training courses nearest you.

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

• Never permita guest to operate this ATV unless the guest has read this manual

and all product labels, and has completed a certified training course.

• Always avoid operating an ATV on any paved surfaces, including sidewalks,

driveways, parking lots and streets.

• Never operate an ATV on any public street, road or highway, even a dirt or gravel

one.

• Never operate an ATVwithoutwearing an approvedhelmetthatfitsproperly. You

should also wear eye protection (goggles or face shield), gloves, boots, longsleeved shirt or jacket, and long pants.

• Never consume alcohol or drugs before or while operating this ATV.

• Never operate at excessive speeds. Always travel at a speed which is proper

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

• Never attempt wheelies, jumps or other stunts.

• Always inspect your ATVeach time you use it to make sure it is in safe operating

condition. Always follow the inspection and maintenance procedures and schedules described in this manual.

• Always keep both hands on the handlebars and both feet on the footrests of the

ATV during operation.

• Always go slowly and be extra careful when operatingon unfamiliar terrain. Al-

ways be alert to changing terrain conditions when operating the ATV.

• Never operate on excessively rough, slippery or loose terrain.

• Always follow proper procedures for turning as described in this manual. Prac-

tice turningat low speeds beforeattemptingto turn at fasterspeeds. Do notturn at excessive speed.

• Always have the ATV checked by an authorized Polaris dealer if it has been in-

volved in an accident.

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

on smaller hills before attempting larger hills.

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• Always follow proper procedures for climbing hills as described in this manual.

Check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttlesuddenly or make sudden gear changes. Never go over the top of any hill at high speed.

• Always follow proper procedures for going down hills and for braking on hills as

described in this manual. Check the terrain carefullybefore you startdown any hill. Shift your weight backward. Never godownahillat high speed. Avoid going down a hill at an angle which would cause thevehicletoleansharply to oneside. Go straight down the hill where possible.

• Always follow proper procedures for crossing the side of a hill as described in this

manual. 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 have mastered the turning technique described in this manual on level ground. Avoid crossing the side of a steep hill if possible.

• Always use proper procedures if you stall or roll backwards when climbing a hill.

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

• Always check for obstacles before operating in a new area. Never attempt to

operate over large obstacles, such as large rocks or fallentrees. Always follow proper procedures when operating over obstacles as described in this manual.

• Always be careful of skidding or sliding. On slippery surfaces, such as ice, go

slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.

• Never operate an ATV in fast flowing water or inwater deeper than that specified

in this manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them lightly several times to let friction dry out the pads.

• Always be sure there are no obstacles or people behind you when you operate

in reverse. When it is safe to proceed in reverse, go slowly. Avoid turning at sharp angles in reverse.

• Always use the size and type tires specified in this manual. Always maintain

proper tire pressure as described in this manual.

• Never modify an ATV through improper installation or use of accessories.

• Never exceed the statedload capacity for an ATV. Cargo should be properly dis-

tributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater distance for braking.

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

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indicates a potential hazard which couldresultinseriousinjuryor death.

WARNING

Additional Important Information...

Due to our concern for the safety of our customers and the general public, Polaris hereby strongly recommends and requests that consumers not have installed on a Polaris ATV any equipment which is intended to increase the speed or power of thevehicle;ormakeany other modificationsto the vehiclefor these purposes. Any modifications to the original equipment of the ATV substantially increase the risk of bodily injury. Please be aware that these modifications may create a substantial safety hazard.

Polarishereby informs you that the warranty on your ATV is terminated if any such equipment has been added to the ATV or any modifications have been made to the ATV which increase its speed or power.

We also advise you to strictly follow the recommendedmaintenance program outlined in this manual. This preventive maintenance program is designed to ensure that all critical components on the ATV are thoroughly inspected by your dealer at various mileage intervals.

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 ATV.

Be certain any accessories added to this ATV have been approved by Polaris.

Familiarize yourself with their function and affect on the ATV.

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The Polaris Preferred

Registered Owners

(PRO) Family

Your Owners Program

As the owner of a new Polaris vehicle, you are entitled to a FREE two- year membership in the Polaris PRO Family---the Preferred Registered Owners Family. It’s an owners program forPolaris owners likeyou, people who have chosen the finest recreationalvehicle available, people who share an interestin Polaris and its products.

Once your new vehicle’s warranty is registered, you will receive a PRO Family membership packet that will include:

A letter of welcome to the PRO Family A PRO Family card with your name and membership number A colorful sticker of the PRO logo A PRO merchandise brochure and order form.

As a PRO Family member, you’re entitled to opportunities such as:

A free subscription to PRO Spirit, the official magazine of the PRO Family The chance to buy insurance for your Polaris vehicle. The toll-free insurance

telephone number is: 1-800-473-0111

The chance to arrange travel through the Polaris Travel Center. The toll-free

travel telephone number is: 1-800-267-1915

The chance to apply to serve on PRO Consumer Councils that provide input

into the Polaris vehicles of the future

The chance to serve as a PRO Field Evaluator and provide feedback on your

new vehicle

The chance to take part in national PRO snowmobile, ATV or personal water-

craft rides

The chance to purchase exclusive PRO Family merchandise And more!

To order PRO merchandise, complete the order form you receive with your membership packet, take the form to your Polaris dealer and pay for the merchandise. The merchandisewillbe shipped directly to your home fromthe PRO merchandise fulfillment center.

Watch for your PRO membership packet and the next issue of PRO Spirit magazine. This quarterly magazine will keep you informed about Polaris news and events, and special PRO merchandise, travel, and ride opportunities.

Enjoyyour new Polaris vehicle,and welcome to the family--ThePolarisPROFamily.

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CONTENTS

UNDERSTANDING WARNINGS 1-2..........................

SAFETY WARNING AND OPERATION DECALS 3-13...........

DAILY PRE-RIDE INSPECTION 14...........................

OPERATION WARNINGS 15-33..............................

VEHICLE IDENTIFICATION NUMBERS 34.....................

CONTROL AND PARTS FUNCTIONS 35-54...................

STARTING THE ENGINE 55.................................

VEHICLE BREAK IN PERIOD 56-57..........................

RIDING GEAR 58...........................................

CARRYING LOADS 59......................................

CARGO WEIGHT DISTRIBUTION 60.........................

DAILY PRE-RIDE INSPECTION 61...........................

RIDING 62-72..............................................

BATTERY 73-74............................................

NOISE EMISSION CONTROL SYSTEM REGULATION 75.......

MAINTENANCE 76-121.....................................

TROUBLE SHOOTING 122.................................

WARRANTY 123-124.......................................

INDEX 125................................................

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UNDERSTANDING WARNINGS

ATTENTION:

This is an ADULT VEHICLE ONLY; not a toy. Operation is prohibited for anyone under 16 years of age. READ AND UNDERSTAND WARNINGS AND OWNER’S MANUAL BEFORE OPERATION.

KNOW YOUR VEHICLE BEFORE YOU BEGIN RIDING!

Read this manual thoroughly referring to the various areas which are being discussed on your machine. Operating this vehicle carries with it responsibilities for your personal safety, the safety of others, and the protection of our environment.

SAFETY TRAINING

When you purchased this vehicle your dealer presented a hands-on safety training course covering all aspects of ATVsafety. In addition, you were provided with certain printed material which instructs you on safe operating procedures.

Youshould review thisinformation on a regular basis. In the event you purchased a used Polaris ATV from a party other than a Polaris dealer, you can obtain this safety training at no charge from any authorized Polaris dealer.

Failure to follow the warnings contained in this manual can result in SERIOUS IN-

JURY OR DEATH.

NOTE: Illustrations used in this manual are for general representation only. Your model may differ.

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UNDERSTANDING WARNINGS

SAFETY ALERT

The following precautionary signal words are used throughout this manual to convey the following messages:

This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. Your safety is involved!

WARNING

Indicates a potential hazard which could result in serious injury or death.

CAUTION

Indicates a potential hazard which may result in minor personal injury or damage to the ATV.

NOTE

The word “NOTE:” in this manual will alert you to key information or instructions.

WARNING

HAZARD Failure to heed WARNINGS.

WHAT CAN

HAPPEN WARNINGS identify special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life.

HOW TO AVOID THE

HAZARD Read all WARNINGS in this manual carefully and for your safety be sure to follow their instructions.

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SAFETY WARNING AND OPERATION DECALS

NOTE:

Warning decals have been placed on the vehicle for your protection. Read and follow the instructions on each decal carefully. In the event any decal becomes illegible or comes off, contact your Polaris dealer for a replacement. Any safety decalneeding replacementwillbe providedby Polarisat no charge. The part number is printed on the decal.

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SAFETY WARNING AND OPERATION DECALS

7077919

E1997

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SAFETY WARNING AND OPERATION DECALS

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SAFETY WARNING AND OPERATION DECALS

25_

READ AND UNDERSTAND WARNINGS AND OWNER’S MANUAL BEFORE OPERATION. SEVERE INJURY OR DEATH CAN RESULT FROM IGNORING WARNINGS OR IMPROPER USE. IF YOU DO NOT HAVE THE OWNER’S MANUAL FOR THIS VEHICLE. CALL 1-800-342-3764 TO HAVE ONE PROVIDED AT NO EXTRA CHARGE.

TO REDUCE TIPOVER RISK, BE ESPECIALLY CAREFUL WHEN ENCOUNTERING OBSTACLES AND SLOPES, WHEN BRAKING ON HILLS OR DURING TURNS.

KEEP FEET ON FOOTRESTS AT ALL TIMES. HILL CLIMBING IS DANGEROUS, and should be attempted only by

experienced operators. Start on shallow slopes and practice procedures described in Owner’s Manual before trying steeper terrain. Some hills are too steep to safely stop or recover from an unsuccessful climbing attempt. Effectiveness of brakes is significantly reduced on hills.

Never operate this ATV on grades steeper than 25 degrees . If vehicle slides backwards down hill, apply hand brakes with gradual, even pressure to avoid flipover. Never open throttle suddenly as flipover may result.

REDUCE SPEED when operating this vehicle on rough or hilly terrain, or when carrying cargo on the racks.

REVERSE OPERATIONCANBEDANGEROUS even at low speeds. Steering control becomes difficult. When backing up, proceed slowly and apply hand brakes carefully; aggressive braking may result in flipover. Avoid backing downhill. Avoid turning at sharp angles in reverse.

USE OVERRIDE FOR REVERSE SPEED LIMITERWITHCAUTION; It allows full engine power and can result in excessive speeds. Never activate override button while throttle is open, as loss of control may result.

STOPPING DISTANCE MAY INCREASE with wet brakes or on wet surfaces. AUXILIARY FOOT BRAKE: The right foot auxiliary brake pedal operates the

rear brake only. When backing up or when operating on hills, avoid sudden use of the auxiliary brake; aggressive braking may result in flipover.

PARK BRAKE MAY RELAX WHEN USED FOR LONG PERIODS. When parking on grades, leave the gear shift in forward and don’t leave brake engaged for more than 5 minutes.

VEHICLE DESIGNED MAINLY FOR WARMWEATHERUSE. Throttle linkage and brakes may stick if operated in freezing weather, causing loss of control. Dirt, mud, water, or other contaminants can also affect operation of controls. Check both frequently.

ENGINE SHUT OFF SWITCH is available for use in event of throttle failure or other emergency when engine shut off is desired.

NEVER PERMIT A GUEST TO OPERATE THIS ATV unless the guest has read the Owner’s Manual and all labels, and has completed a certified training course.

7078354

CAUTION: Do not shift transmission while vehicle is moving.

W ARNING

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SAFETY WARNING AND OPERATION DECALS

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SAFETY WARNING AND OPERATION DECALS

WARNING

OVER-LOADING CAN CAUSE STEERING, TIPPING AND BRAKING PROBLEMS RESULTING IN LOSS OF C ON TR OL .

LOSS OF CONTROL CAN CAUSE SEVERE INJURY OR DEATH.

DO NOT OVERLOAD THE ATV. SEE YOUR OWNER’ S MANUAL.

7072786

W ARNING

DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch.

7074954

(Found on models with no racks)

(Found on models with racks)

“IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL.

LOSS OF CONTROL CAN RESULTIN SEVERE INJURY OR DEATH.”

TIRE PRESSURE (PSI):

FRONT __ REAR __

MAXIMUM WEIGHT CAPACITY

(Gross Vehicle Weight)

INCLUDING MACHINE, DRIVER

AND CARGO IS ______ LBS.

(Refer to your Owner’s Manual Supplement for your vehicle’s specifications.)

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.

7078253

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SAFETY WARNING AND OPERATION DECALS

W ARNING

LOAD DISTRIBUTION WARNINGS

Correct loading of this vehicle is necessary to maintain proper stability and operating characteristics. Overloading or incorrect positioning of the load effects the vehicles turning, stopping distance and stability. Failure to follow loading requirements could cause severe injury or death. REDUCE SPEED AND ALLOW GREATER DISTANCE FOR BRAKING WHEN CARRYING CARGO.

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. Maximum cargo capacity is 270 lbs. on level terrain. When operating at maximum cargo capacity, the cargo weight distribution must be 90 lbs. on the front rackand 180 lbs. on the rear rack.

ALL LOADS MUST BE SECURED BEFORE MOVING VEHICLE. Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle.

LOADS MUST BE CARRIED AS LOW ON THE RACKS AS POSSIBLE. Carrying loads high on the racks raises the centerof gravity of the vehicle and creates a less stable operating condition. When cargo loads are carried high on the racks, the weightof the loads must be reduced to maintain stable operating conditions.

OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When handling offcentered loads which cannot be centered, securely fasten load and operate with extra caution.

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.

DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the front rack. SEE YOUR OWNER’S MANUAL.

7074110

This decal is found only on models with dual racks.

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SAFETY WARNING AND OPERATION DECALS

W ARNING

RACK LOAD WARNINGS

MAXIMUM CARGO CAPACITY is 125 lbs. on level terrain. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions.

ALL LOADS MUST BE SECURED BEFORE MOVING VEHICLE. Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle.

LOADS MUST BE CARRIED AS LOW ON THE RACK AS POSSIBLE. Carrying loads high on the rack raises the center of gravity of the vehicle and creates a less stable operating condition. When cargo load is carried high on the rack, the weight of the load must be reduced to maintain stable operating conditions.

OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When handling off-centered loads which cannot be centered, securely fasten load and operate with extra caution.

EXTREME CAUTION MUST BE USED when operating with loads extending over the rack sides. Stability and maneuverability may be adversely affected, causing the machinetooverturn.

SEE YOUR OWNER’S MANUAL. 7074173

This decal is found on models with only rear racks.

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SAFETY WARNING AND OPERATION DECALS

ATTENTION

DOPERATION OF THIS VEHICLE WITHOUT

THE FILTER ELEMENT WILL SEVERELY DAMAGE THE ENGINE.

DCLEAN AIR FILTER OFTEN, MORE FRE-

QUENT CLEANING REQUIRED IN DUSTY CONDITIONS.

DLiutilisation de ce véhicule sous liélément

filtre endommage sévèrement le moteur.

DNettoyer souvent le filtre à air, surtout dans

des situations poussiereuses.

7072791

(Under Seat)

(on rear of seat)

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SAFETY WARNING AND OPERATION DECALS

MOVING PARTS HAZARD UNDER BELT-CLUTCH GUARD. TO PREVENT SERIOUS INJURY, DO NOT OPERATE VEHICLE WITH G UARD REMOVED.

DO NOT MODIFY ENGINE OR CLUTCH. DOING SO CAN CAUSE PART FAILURE, POSSIBLE IMBALANCE, AND EXCESSIVE ENGINE RPM WHICH CAN RESULT IN SERIOUS INJURY OR DEATH.

NO STEP

7078689

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SAFETY WARNING AND OPERATION DECALS

ALL WHEEL

DRIVE

SWITCH

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

7074935

MANUFACTURED BY: POLARIS IND

DATE:

VIN:

THIS VEHIC LE IS AN ALL TERRAIN VEHICLE AN D IS NOT INTENDEDFOR USE ON PUBLICROADS.

PRINTED IN U.S.A.

7077185

CE VÉHICULEEST UN VÉHICULE TOUT TERRAIN QUI NiEST PAS DESTINÉ À ÊTRE UT ILISÉ SUR LES CHEMIN S PUBLICS.

ATTENTION

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

Factory setting:

40° to 80° F. at 0-3000 feet. (+5° to 26° C. at 0-900 meters). 7073761

TRAILER MAX. WEIGHT 850 LB S.

HITCH MAX. VERTICAL WEIGHT 30 LB S.

POIDS MAX. DE REMORQUE 386 KG.

POIDS MAX. VERTICAL D’ATTACHE 14 KG.

OVERRIDE

SWITCH

Reverse override and all wheel drive activation in reverse is controlled by the override switch. See your Owner’s Manual.

7076273

Reverse Speed is limited.

Reverse override is controlled by the override switch.

See your Owner’s Manual.

OVERRIDE

SWITCH

7076274

AWD Models 2WD Models

7077542

TRAILER MAX WEIGHT: 1250 LBS. (568 KG) ON LEVEL GROUND 850 LBS. (368 KG) UP TO 15° GRADE

HITCH MAX. VERTICAL WEIGHT:30 LBS. (14KG)

7072533

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

Torque Eccentric Bol ts To 60 Ft. Lbs .

7077618

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DAILY PRE-RIDE INSPECTION

Inspect your ATV each time before riding to ensure it is in proper working order. If proper inspection is not done, severe injury or death could result.

WARNING

If a proper inspection is not performed serious injury or death can result. Always inspect your ATV before riding following the checklist carefully. Before riding your vehicle, inspect all operating controls and parts.

Item/Inspection Procedure

1.Tires - check condition and pressures

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

3.All brakes -check operation, adjustment and fluid level (includes auxiliary brake)

4.Throttle - check for free operation and closing

5.Headlight/Taillight/Brakelight - check operation of all indicator lights and switches

6.Engine stop switch - check for proper function

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

8.Drive chain - condition and slack; refer to drive chain adjustment

9.Air cleaner element - check for dirt; clean or replace

10.Steering - check for free operation noting any unusual looseness in any area

11.Loose parts- visually inspect vehicle for any damaged or loose nuts/ bolts or fasteners

12.Operators helmet, goggles and clothing

13.Engine coolant - (Liquid Cooled Models Only) check for proper level at the recovery bottle

Page 23

OPERATION WARNINGS

WARNING

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 tooperate 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 trainingcourseofferedby Polaris IndustriesInc. They should then 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

Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child.

Even though a child may be within the age group for which some ATVs are recommended, he or she may not have the skills, abilities, or judgment needed to operate the ATV safely and may be involved in a serious accident.

HOW TO AVOID THE

HAZARD

No one under 16 should operate a Polaris ATV.

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OPERATION WARNINGS

WARNING

POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN

HAPPEN Greatly reduces your ability to balance and control this ATV. Couldcause an accident, resultinginharm to youand/or your passenger. HOW TO AVOID THE

HAZARD

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

Page 25

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD Operating this ATV on paved surfaces, including sidewalks, paths,

parking lots, and driveways. WHAT CAN

HAPPEN

The ATV tires are designed for off-road use. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of control.

HOW TO AVOID THE

HAZARD

Avoid operating the ATV on pavement whenever possible. If you must ride on a paved surface, go slowly and do not make sudden turns or stops.

Page 26

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN

HAPPEN You can collide with another vehicle. HOW TO AVOID THE

HAZARD

Never operate this ATV on any public street,road or highway,even a dirt or gravel one.

In many states it is illegal to operate ATVs on public streets, roads and highways.

Page 27

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD OperatingthisATVwithoutwearingan approved helmet, eye protection

and protective clothing. WHAT CAN

HAPPEN

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

Operating without eye protection c an result in an accident and increases your chances of a severe injury in the event of an accident.

HOW TO AVOID THE

HAZARD Always wear an approved helmet which fits properly. You should also wear:

Deye protection (goggles or face shield); Dgloves; Dboots; Dlong-sleeved shirt or jacket; and Dlong pants.

Page 28

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN

HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident. HOW TO AVOID THE

HAZARD

Never consume alcohol or drugs before or while driving this ATV.

POTENTIAL

HAZARD Operating this ATV at excessive speeds. WHAT CAN

HAPPEN

Increasesyourchances of losing control of the ATV,which c an result in an accident.

HOW TO AVOID THE

HAZARD

Always travel at a speed which is proper for the terrain, visibility and operating conditions; and your experience.

Page 29

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN

HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE

HAZARD

Neverattempt stunts, such as wheeliesorjumps. Don’t try to show off.

Page 30

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN

HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE

HAZARD

Always inspect your ATV each timeyou use itto make sure theATV is in safe operating condition.

Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual.

POTENTIAL

HAZARD

Removing hands from handlebars or feet from footrests during operation.

WHAT CAN

HAPPEN

Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off the ATV. If you remove a foot from the footrest, your foot or leg may come into contactwith the rear wheels, which could injureyou orcause an accident.

HOW TO AVOID THE

HAZARD

Alwayskeep both hands on thehandlebarsandboth feeton the footrests of your ATV during operation.

Page 31

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD Failure to useextracarewhenoperatingthis ATVonunfamiliarterrain. WHAT CAN

HAPPEN

You can come upon hidden rocks, bumps, or holes, without enough time to react.

Could result in the ATV overturning or going out of control. HOW TO AVOID THE

HAZARD Go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the

ATV.

Page 32

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slip-

pery or loose terrain. WHAT CAN

HAPPEN

Could cause loss of traction or vehicle control, which could result in an accident, including an overturn.

HOW TO AVOID THE

HAZARD

Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATVonsuchterrain.

Always be especially cautious on these kinds of terrain.

Page 33

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD Turning improperly. WHAT CAN

HAPPEN ATV could go out of control, causing a collision or overturn. HOW TO AVOID THE

HAZARD

Alwaysfollowproper procedures for turning as described in the Owner’s Manual. See page 63 .

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

Do not turn at excessive speed.

POTENTIAL

HAZARD Operating on excessively steep hills. WHAT CAN

HAPPEN

The vehicle can overturn more easily on extremely steep hills than on level surfaces or small hills.

HOW TO AVOID THE

HAZARD Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting large hills. Never operate ATV on hills steeper than 25_.

Page 34

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD Climbing hills improperly. WHAT CAN

HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE

HAZARD

Always follow proper procedures for climbing hills as described in the Owner’s Manual. See pages 65 through 68.

Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Neveropen the throttle s uddenly. The ATVcould flipoverbackwards. 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.

Page 35

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD Going down a hill improperly. WHAT CAN

HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE

HAZARD

Always follow proper procedures for going down hills as described in the Owner’s Manual. See page 67. NOTE: A special technique is required when braking as you go downhill.

Always check the terrain carefully before you start down any 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. Go straight down the hill where possible.

Page 36

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN

HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE

HAZARD

Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner’s Manual on level ground. See page 68. Be very careful when turning on any hill.

Avoid crossing the side of a steep hill if possible. When crossing the side of a

hill: Alwaysfollowproper procedures as describedinthe Owner’sManual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.

Page 37

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN

HAPPEN Could result in ATV overturning. HOW TO AVOID THE

HAZARD Maintain steady speed when climbing a hill. Ifyouloseallforward

speed: Keep weight uphill. Apply the brakes. Lock parking brake after you are stopped. If you begin rolling

backwards: Keep weight uphill; never apply engine power. Never apply the rear brake while rolling backwards. Apply the single-lever brake gradually. When fully stopped, apply rear brake as well, and then lock parkingbrake. Dismount on uphill side, or to either side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in

the Owner’s Manual. See page 68.

Page 38

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN

HAPPEN Could cause loss ofcontrolora collision. Could cause theATVtooverturn. HOW TO AVOID THE

HAZARD Before operating in a new area, check for obstacles. Use extreme caution when ridingover large obstacles,such as large rocks

or fallen trees. If you cannot avoid obstacles, always follow proper procedures as de-

scribed in the Owner’s Manual.

POTENTIAL

HAZARD Skidding or sliding. WHAT CAN

HAPPEN You may lose control of the ATV. You may also regain traction unexpectedly, which may cause the ATV to

overturn. HOW TO AVOID THE

HAZARD

On slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.

POTENTIAL

HAZARD Riding on frozen lakes and rivers. WHAT CAN

HAPPEN

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

HOW TO AVOID THE

HAZARD

Never ride your ATV on a frozen body of water before you are sure the ice isthickenough and sound enough to support the machineand its operator, as well as the force that is created by a moving vehicle.

Page 39

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD Operating this 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.

HOW TO AVOID THE

HAZARD

Never operate this ATV in fast flowing water or in water deeper than that specified in your Owner’s Manual. See page 69.

Remember that wet brakes may have reduced stopping ability. Test your 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

You could hit an obstacle or person behind you, resulting in serious injury.

HOW TO AVOID THE

HAZARD

When you select reverse gear,make sure there are no obstacles or people behind you. When it is safe to proceed, go slowly.

Page 40

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD OperatingthisATVwithimproper tires, or with improper or uneven tire

pressure. WHAT CAN

HAPPEN

Use of impropertiresonthisATV,oroperationofthisATVwith improper or uneven tire pressure, may cause loss of control, and increases the risk of an accident.

HOW TO AVOID THE

HAZARD

Always use the size and type tires specified in the Owner’s Manual Supplement for this vehicle.

Always maintain proper tire pressure as described in the Owner’s Manual Supplement.

POTENTIAL

HAZARD Operating this ATV with improper modifications. WHAT CAN

HAPPEN

Improperinstallationof accessoriesormodification of thisvehiclemay cause changes in handling which in some situations could lead to an accident.

HOW TO AVOID THE

HAZARD

Never modify this ATV through improper installation or use of accessories. All parts and accessories added tothis vehicle should be genuine Polaris Industries Inc. or equivalent components designed for use on this ATV; and should be installed and used according to instructions.If you have questions,consult an authorizedPolarisATV dealer.

Page 41

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN

HAPPEN

Could cause changes in vehicle handling which could lead to 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 greater

distance for braking. Alwaysfollowthe instructionsin the Owner’s Manual for carrying car-

go or pulling a trailer. See pages 59 and 60.

After a rollover or an accident, have a qualified service dealer check the complete machine including,but not limited to,brakes, throttleand steering for possible damage.

WARNING

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

CAUTION: Keep combustible materials away fromexhaust system. Fire may result.

Page 42

VEHICLE IDENTIFICATION NUMBERS

2Onrecoil housing

1 VIN on the lower left side of the frame tube

Important: Record these numbers from your ATV in the spaces provided.

1. Frame VIN

2. Engine Serial Number (Right front side of engine crankcase)

Remove the spare key and store in a safe place. Your key can be duplicated only by obtaining a key blank fromPolaris and having it cut by matingitwithyour existing key.

The vehicle frame and engine serial numbers are importantfor model identification when registering your vehicle, obtaining insurance or whenever replacement parts are required. In the event your vehicle were stolen these numbers are essential to the recovery and identification of your ATV.

Dealer Imprint

Page 43

CONTROL AND PARTS FUNCTIONS

Engine Electrical Switches

1. Override Switch (Reverse Speed Limiter)- This vehicle is equipped with a re-

verse speed limiter system. To obtain additional power while backing up, depress the override button. WARNING: Never activate the override button while throttle is open as loss of control may result, causing severe personal injury or death.NOTE: The override switch also allows activation of Demand 4 Drive (All Wheel Drive) in reverse, if Demand 4 Drive switch is on.

2. Main Switch - This switch must be turned clockwise to the “on” position to start the engine.

3. Emergency Engine Stop Switch - 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 stuck throttle or other emergency. NOTE: Both the main switch and the emergency engine stop switch shut off all electrical powertothe entirevehicleincludinglights. Tostopthe engine,slidethestopswitch right or left to the “off” position.

4. Engine Start Button - Slide thestop switchto the center “run” position and push up to start.

WARNING

Backing your ATV can be dangerous!

You could hit an obstacle or person behind you; or the vehicle could tip over rearward on a steep incline causing severe injury or death.

Alwaysback slowly avoiding excessive speed and do not use the reverse speed override switch system unless additionalpower is requiredfor vehicle movement.

Avoid backing on steep inclines. Avoid turning at sharp angles in reverse.

RUN

OFFOFF

Push Up to Start

Page 44

CONTROL AND PARTS FUNCTIONS

Light Switches and Indicator Lights

Switches

Each Polaris ATVhas a main switch. It is located on the righthand side of the machine and operated with a key.

The light switch is located on the left hand handlebar. In addition to turning the lights on and off, it also switches the lights from Hi to Lo on models equipped with Hi-Lo beams. NOTE: Will not light unless the main switch is on.

Indicator Lights

Each Polaris ATV has indicator lights. The configurationof these lights differs with individualmodels and not every model is equipped with all the lights. The informationinyourOwner’sManualSupplementandin the followingbox will help youidentify the lights on your machine and their function.

High Beam Indicator (Blue)

Transmission Neutral indicator - Green

Transmission Reverse indicator - Yellow

All Wheel Drive

Indicator - Red

(Refer to page

43 for location)

Low Oil Warning Light (Red)

Engine Hi Temp Warning Indicator

If your machine has the following light configuration, use this diagram to determine indicator light location and function.

Hi Temp Warning - Red (will light only if engine overheats)

Neutral - Green

Reverse - Yellow

Located in LH switch on models equipped with Hi-Lo beam lights.

Page 45

CONTROL AND PARTS FUNCTIONS

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

WARNING

This ATV is not equipped with highway approved lighting. This ATV is designed for off-road use only and must not be ridden on streets or highways. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness.

NOTE: The taillight is on whenever the mainswitch (key) is in the onposition. Turn the key off to prevent battery drain.

indicates a potential hazard which couldresultinseriousinjuryor death.

WARNING

Electronic Speedometer

Some Polaris ATVs are equipped with an electronic speedometer which senses vehicle speed from the right hand front wheel. The electronic speedometer measures distance in miles and kilometers as well as hours of operation. To display each mode, press the button on the face of the speedometer once to “toggle” through the functions. Each function will be displayed as follows:

Miles 00000.0 M Trip Miles 000.0 M Hours 00000.0 H

To reset Trip Miles:

1.Toggle to Trip Miles

2.Hold down button approximately 4 seconds.

To change distance measurement from Miles to Kilometers or vice versa:

1.Toggle to odometer.

2.Hold down the button approximately 8 seconds until the word FARIA appears in the display, then release the button. If the last digit in the display is a “K”, the measurement is Kilometers,if the last digit is an“M”,themeasurementisMiles.

The speedometer also includes a reverse speed limitfunction that limits the ATV’s speed in reverse after approximately 7 to 9 mph. Refer to page 35 for additional information.

ATTENTION

Do not wash the electronic speedometer with a high pressure washer. Wash the unit by hand or with a garden hose. High water pressure may allow water to enter the speedometer and cause damage to the electronic components

Page 46

CONTROL AND PARTS FUNCTIONS

Engine Throttle and Choke

Throttle Lever

Engine speed and vehicle movement are controlledby pressing the throttle lever. The throttle lever is spring loaded and engine speed returns to idle when the lever is released. This vehicle is equipped with a Polaris Electronic Throttle Control (ETC) which is designed to reduce the risk of a frozen or stuck throttle. In the event the throttle cable should stick in an open position, the engine will stop and power to the rear wheels will cease when the operator releases the throttlelever.

Choke Lever

Refer to the engine starting procedure on page 55 for correct choke and throttle settings during starting.

WARNING

The Electronic Throttle Control (ETC) stops the engine in the event of a throttle system malfunctionand 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 throttlecontrols. A stuck or improperlyoperating throttlecould cause an accident resulting in severe injury or death.

Always contact your dealer for service repairs whenever throttle problems arise.

Failure to check or maintain proper operation of the throttle system can result in the throttle lever sticking during riding and cause an accident.

Always check the lever for free movement and returnbefore starting the engine and occasionally during riding.

Throttle

Choke

Page 47

CONTROL AND PARTS FUNCTIONS

Front and Rear Brakes

The brake fluid in the master cylinder, which is located on the left handlebar, should be checked before each ride. The fluid level can be seen through the plastic reservoir, and should be maintained between the indicated max and min marks on the reservoir. NOTE: When checking the fluid level, the ATV must be on level ground the the handlebars straight.If the fluid level is low add DOT 3 (PN 2870990) only.

WARNING: Once a bottleof brake fluid is opened, use what is necessary and discard the rest. Do not storeor use a partialbottleof brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. This causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of serious injury.

The front and rearbrakes are applied by squeezing the left side brake levertoward the handlebar. The front and rear brakes are hydraulically activated disc type brakes which are activated by one lever only.

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

WARNING

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

Never operate the ATV with a spongy feeling brake lever.

Master Cylinder Reservoir

Max

Min

Page 48

CONTROL AND PARTS FUNCTIONS

Parking Brake

Setting the Parking Brake

1.Squeeze the left hand brake lever two or three times and hold it.

2.Rotate the park brake lock into the notcheson the master cylinderbody. Release the brake lever.

3.To release the parking brake lock, squeeze the brake lever. Itwillreturn to its released position.

WARNING

Always check to be sure thatthe parking brake has been disengaged before operating the ATV. An accident could result if the parking brake is left on while the ATV is operated.

The parking brake may relax when left on for a long period of time. This could cause an accident.

Do not leave the vehicle on a hill depending on the parking brake for more than five minutes.

Always block the downhill side of the wheels if leaving the ATV on a hill or park the ATV in a side hill position.

Auxiliary Power Outlet

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

Outlets are located on the front headlight pod and/or rear taillight bracket. Do not use frontand rear outlets simultaneously as increased battery drain will re-

sult. To determine if your vehicle is equipped with auxiliary power outlets, please check

your Owner’s Manual Supplement.

Parking Brake Lock

Minimum

Maximum

Page 49

CONTROL AND PARTS FUNCTIONS

Auxiliary Brake

Your Polaris ATV has an auxiliary brake provided as a safety feature. It is located on the inside of the right floor board and is operated by the rightfoot. It is intended as a backup to the main brake system, especiallyif the main system becomes inoperative.

WARNING: Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward or the rear wheels may skid and slide sideways causing loss of control. If the rear wheels slide, reduce brake pedal pressure to brake the rear wheels without skidding. Aggressively applying the rear brake when backing down a hill may cause rear tip over.

Brake Fluid Level

It will be necessary to check the brake fluid level for the auxiliary brake system. The reservoir is located under the seat or near the foot brake. The fluid should be kept between the maximum and minimum marks.

Auxiliary Brake Pedal

Page 50

CONTROL AND PARTS FUNCTIONS

Transmission Gear Selector Operation

Shiftpatternsdepend on the type ofvehicle you own. Please check your Owner’s Manual Supplement to define your machine’s shift pattern.

The transmission gear selector is located on the right side of the vehicle directly above and forward of the engine recoil starter. The transmission selector lever has three or fourpositions: high forward;reverse; neutral; and low forwardor forward; reverse; and neutral. Check your Owner’s Manual Supplement for specification.

Use of low forward gear is recommended in heavy pulling situations to extend belt life.

To change gears, stop the vehicle and with the engine idling, move the lever to the desired gear. Do not attempt to shift gears with engine speed above idle or while the vehicle is moving.

Always place the transmissionin gear with the parking brake locked whenever the vehicle is left unattended.

Maintaining shift linkage adjustment is important to assure proper transmission function. Should you experience any shifting problem see your dealer.

WARNING

1.Do not attempt to shift the transmission while the vehicle is moving or while operating on hilly terrain.

2.Always place the transmission in gear with the parking brake applied and turn the vehicle off whenever the vehicle is left unattended.

Shift Patterns

Page 51

CONTROL AND PARTS FUNCTIONS

Demand 4 Drive

AWD Switch

Exclusive Demand 4 Drive System (All Wheel Drive)

Polaris4wheel drive ATVsare equipped with a unique, Polaris exclusive,Demand 4 Drive (AWD) system which is activated by a switch on the righthandlebar. When the switch is “off” the 4x4 is in 2 wheel drive at all times. When the switch is “on” the 4x4 is in Demand 4 Drive and the front wheels will automatically engage anytime the rear wheels lose traction. When the rear wheels regain traction, the front wheels will automatically disengage. NOTE: The override switch also allows activation of Demand 4 Drive (AWD) in reverse, if Demand 4 Drive switch is on.

There is no limit to the length of time the vehicle may remain in Demand 4 Drive. The Demand 4 Drive switch may be turned on or off while the vehicle is moving.

If the switch is turned off when the front hubs are driving they will not release until the rear wheels regain traction.

CAUTION: Do not switch on Demand 4 Driveif the rear wheels are spinning. This may cause severe drive shaft and clutch damage. Engage the Demand 4 Drive switch before getting into conditions where front wheel drive may be needed. Ifthe rear wheels are spinning, release the throttle before turning the Demand 4 Drive switch on.

Page 52

CONTROL AND PARTS FUNCTIONS

Disengaging Wheel Hubs

When backing uphillwhileinDemand 4 Drive and then goingforwarddownhill,one or both hubs may remain engaged. If one or both hubs remain engaged they can be disengaged by stopping, shifting to and moving in reverse. Then proceed in forward again.

You can tell if only one front hub is engaged if the handlebars pull to one side. If bothfrontwheelhubs are engaged, steeringeffortincreases but remains balanced from left to right, and vehicle speed is somewhat restricted.

WARNING: If both hubs were engaged and only one releasedduringopera-

tion, loss of control could result. If you experience hub engaging symptoms, use the above disengaging technique before proceeding. Failure to disengage front hubs as directed above could result in severe injury or death.

Ifthehubs remainengaged after followingthese instructionsreturn the ATV toyour dealer for service.

PVT System

WARNING

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

DDo not modify any component of the PVT system. Doing so may re-

duce its strength so that a failure may occur at high speeds. This system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components.

DRoutine maintenance is the responsibility of the owner. Always follow

recommended maintenance procedures. See your dealer!

DThis PVT system is intended for use on Polaris products only. DThe PVT housing must be securely in place during operation.

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

Page 53

CONTROL AND PARTS FUNCTIONS

Engine Cooling System

Coolant Level

The recovery bottle, located on the left side of the machine, must be maintained between the minimum and maximumlevelsindicatedon the recovery bottle.

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

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

NOTE: Some coolant level drop on new machines is normal as the system is purging itself of trapped air. Observe coolant levels and maintain as recommended by adding coolant tothe recovery bottle. Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. NOTE: Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. NOTE: Always follow the manufacturer’smixingrecommendations for the freeze protection required in your area.

To access the recovery bottle on Gen IV machines it is necessary to remove the left side panel as described on page 91.

Recovery Bottle

Gen III

Recovery Bottle

Gen IV

Page 54

CONTROL AND PARTS FUNCTIONS

Engine Cooling System

Radiator Coolant Level Inspection NOTE: This procedure is only re-

quiredifthe cooling system has been drained for maintenance and/or repair. However, if the recovery bottle has run dry, the level in the radiator should be inspected and coolant added if necessary.

WARNING Never remove the

pressure cap when the engine is warm or hot. Escaping steam can cause severe burns. The engine must be cool before removing the pressure cap.

To access the radiator pressure cap: Gen III - Toaccess the pressurecap,

clean the area aroundthe oil cap and remove the oil cap (2-cycle models). Remove front cover by placing your fingers under the front of the cover and pulling upward. Reinstall oilcap.

Gen IV - Remove the four screw securing front rack. Remove front cover by placing your fingers under the frontof the cover and pulling upward.

NOTE: Use of a non-standard pressure cap will not allow the recovery system to function properly. If the cap should need replacement contact your dealer for the correct replacement part.

Engine Cooling System

To insure that the coolant maintains its ability to protect the engine, it is recommended thatthe system be completelydrained every twoyears andafresh mixture of antifreeze and water be added. Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolantor a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. NOTE: Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. IMPORTANT: Al- ways follow the manufacturer’s mixing recommendations for the freeze protection required in your area.

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

Pressure Cap

Gen III

Rack

Front Cover

Gen IV

Page 55

CONTROL AND PARTS FUNCTIONS

Engine Fuel and Oil System

The fuel tank filler cap (1) is located directly behind the handlebar. Refer to your owner’sManualSupplementfor tank capacity. Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R+ M/2 octane.

On models with a two cycle engine, the engine oil injection tank filler cap (2) is located on the front of the machine. Refer to you Owner’s Manual Supplement to determine the type of engine your vehicle has. The tank capacity is 2 quarts (1.9 l). CAUTION: To avoid serious engine damage always top off the oil level when refueling.

CAUTION: On models with a two cycle engine, use only Polarisinjectionoil. Never substitute or mix oil brands. Serious engine damage and voiding of warranty can result.

The fuel valve is located on the left side of the front fender and has three positions: OFF: For vehicle storage and whenev-

er transporting. ON: For normal operation. RES: For reserve supply in the event of

main supply exhaustion. NOTE: There is 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 having used the reserve supply.

Alwaysreturnvalveto“on”position after refueling machine.

OFF

RES

Page 56

CONTROL AND PARTS FUNCTIONS

Engine Fuel Safety/Fuel/Filter

The Polaris ATV is equipped with a unique in-line fuel filter. This filter should be replaced by your dealer after every 100 hours of operation or

annually. Do not attempt to clean the fuel filter.

WARNING

Gasoline is highly flammable and explosive under certain conditions.

DAlways exercise extreme caution whenever handling gasoline. DAlways refuel with the engine stopped and outdoors or in a well venti-

lated area.

DDo not smoke or allow open flames or sparks in or near the area

where refueling is performed or where gasoline is stored.

DDo not over fill the tank. Do not fill the tank neck. DIf you get gasoline on your skin or clothing, immediately wash it off

with soap and water and change clothing.

DNever start the engine or let it run in an enclosed area. Gasoline

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

DShut off fuel valve whenever the ATV is stored or parked.

WARNING

The engine exhaust from this

product contains chemicals known to cause cancer, birth defects or other reproductive harm.

Page 57

CONTROL AND PARTS FUNCTIONS

4-Cycle Premium 4 Synthetic Lubricant

Polaris Premium 4 All Season Synthetic engine oil has been specially formulated forusein Polaris4-cycleengines. Itisafullysynthetic,high performance,multi-viscosity oil designed to provide the ultimate in lubrication performance and protection.

Premium4 possesses unsurpassedfilmstrengthover thewidest possible temperature range. It resists viscosity and frictional breakdown in ambient temperatures from -40° F to 120° F. Its exceptional frictional properties result in more efficient operation, more power output and lower fuel consumption.

AlthoughPolaris Premium 4 is theonly oil recommended for use in this engine,use of any API certified “SH” oil is allowable. Oil may need to be changed more frequently if Polaris Premium 4 is not used. You will also need to follow the manufacturers recommendations for ambient temperature operation.

Oil System

The oil tank is located on the left side of the vehicle or on the engine, depending on the model. To check the oil:

1. Set machine on a level surface.

2. Start the engine and let it idle for 20-30 seconds.

3. Stop the engine, remove dipstick and wipe dry with a clean cloth.

4. Screw in the dipstick completely, remove it and read the oil level. NOTE: The dipstick must be screwed in to keep the angle and depth of stick consistent.

5. Remove dipstick and check to see that the oil levelis between the fulland add marks. Add oil as indicated by the level on the dipstick. Do not overfill.

CAUTION: Use only Polaris Premium 4 All Season syntheticoil (PN 2871271), or API certified “SH” oil. Never substitute or mix oil brands. Serious engine damage and voiding of warranty can result.

Oil and Filter Change

The recommended oil change interval is 100 hours, 1000 miles, or every six months, whichever comes first. Suggested break in oil change is at 20 hours, 500 miles, or one month, whichever comes first. Severe use operation requires more frequent service. Severe use includes continuous duty in dusty or wet conditions, and cold weatherriding. NOTE: Severe use cold weather riding is all riding below 10° F,and riding between 10° F and 30°F when most trips are slow speed and less than 5 miles. Be sure to change the oil filter whenever changing oil

1. Place vehicle on a level surface.

2. Clean area around drain plug which is found at the bottom of the oil tank or on the bottom of the engine.

ADD 8 OZ. NORMAL FULL

Maintain Oil Level In Normal Range

Page 58

CONTROL AND PARTS FUNCTIONS

Oil and Filter Change (Cont.)

3. Run engine for two to three minutes until warm. Shut engine off.

4. Place a drainpan beneath the plug and remove it. CAUTION: Oil may be hot. Do not allow hot oil to come into contact with skin as serious burns may result.

5. Allow oil to drain completely.

6. Installanew sealing washer on oil drain plug. NOTE: The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs, nicks or scratches.

7. Reinstall drain plug and torque to 14-17 ft. lbs. (1.93-2.35 kg/m)

8. Disconnect the lower oil delivery hose. Remove the fitting (C) from the oil tank. Clean the fitting screen. Reinstall the fitting screen, torquing to 14-17 ft. lbs. Reattach oil line. If banjo fitting (D) is used, torque to 14-17 ft. lbs. If hose clamp (E) is used, tighten securely.

9. Place shop towels beneath oil filter. Using an oil filter wrench, turn filter counterclockwise to remove.

10. Using a clean dry cloth, clean filter sealing surface on crankcase.

11. Lubricate O-Ring on new filter with a film of new engine oil. Check to make sure the O-Ring is in good condition. Also make sure the O-ring from the old filter is not still on the engine.

12. Install new filter and tighten by hand 1/2 to 3/4 turn after gasket contact.

13. Approximately 1 cup of engine oil will remain in the crankcase. To drain, removedrainplugfoundon lower rightsideof crankcase. NOTE: The sealing surfaces on the drain plug and crankcase should be clean and free of burrs, nicks or scratches.

14. Reinstall drain plug.

Page 59

CONTROL AND PARTS FUNCTIONS

15. Remove dipstick and add the amountof oil indicated in your Owner’s Manual Supplement. Reinstalldipstick.NOTE: If sump is not drained, add about 1 3/4 quarts initially.

16. Place gear selector in neutral and set parking brake.

17. Startengine andletit idlefor one to two minutes. Stop engine and inspect for leaks.

18. Re-check oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick.

19. Dispose of used filter and oil properly.

Fuel Filter and Oil Filter

All Polaris ATVs are equipped with a unique in-line fuel filter. These filters should be replaced by your dealer after every 100 hours of operation

or annually. Do not attempt to clean these filters.

Dipstick

Filter

Page 60

CONTROL AND PARTS FUNCTIONS

Polaris 2-Cycle Lubricants

Polaris has a family of premium oils available for use in all our products and highly recommends their use. The only oils recommended for Polaris 2-cycle ATVs are Polaris Premium 2-cycle oil or Premium Gold Synthetic 2-cycle oil.

CAUTION: Engine warranty coverage may become void if other brands are substituted.

Polaris Premium 2-cycle lubricants are the most advanced formulationof oils specifically designed for today’s 2-cycle engines. Months of lab and field tests have resulted in a new generation of 2-cycle lubricants. Polaris Premium 2-cycle lubricants provide additives for 2-cycle engines lacking in today’s fuel that keep ring grooves cleaner for less ring sticking and provide improved overall engine cleanliness. With new generation lubricity technology, they excel in meeting the lubrication demands of today’s high performance 2-cycle engines. These are optimum oils recommended for liquid cooled and air cooled 2-cycle engines. We believe these oils are the best available in the market today.

Premium Gold Synthetic 2-Cycle Oil

Yourvehicle has been primed with Premium Gold Synthetic oil. This lubricanthas been specially formulated for low smoke, low odor and high lubricity. We recommend continued use of this oil or Premium 2-cycle oil.

Premium 2-Cycle Oil

Polaris also has a TC-W3 premium oilavailablefor use in all of our 2 cycle products. We highly recommend its use if premium gold synthetic is not used. The only oil recommended for this ATV is Polaris brand oil.

Polaris Premium 2-cycle oils will readily mix with each other, however do not mix PolarisPremium2-cycle oils with any otheroilsas they may notbe compatible and engine damage may occur.

Page 61

CONTROL AND PARTS FUNCTIONS

Recoil Starter

If the battery is weak and cannot start the engine, use of the recoil starter located on the right side of the machine will allow vehicle operation until repairs can be made. Polaris4-cycle engines are equipped with automatic decompressors. This makes recoilstarting possible by allowing compressionto “leak” at crankingspeeds. The decompressor senses when the engine is spinning fast enough to start and restores compression for starting.

1.Be certain your vehicle is on a level surface and the parking brake is set . See page 40.

2.Take the machine out of gear.

3.Grasp the recoil starter tightly and pull slightly until the starter mechanism engages.

4.Pull the rope abruptly to start the engine. CAUTION: Take care not to extend the starter rope so far that it stops, causing damage to the recoil assembly.

Page 62

CONTROL AND PARTS FUNCTIONS

Draintherecoil housing afteroperatingthe ATV in very wet conditions. This should also be done before storing the ATV. The drain screw is located at the bottom of the recoil housing. Remove the screw with a 10mm wrench. Reinstall screw once housing has been drained.

CAUTION: Make sure the manual start handle is fully seated on the recoil housing, especially when travelling in wet areas. If it is not sealed properly, water may enter the recoil housing and damage components.

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

After travelling in wet areas the recoil housing and starter should always be drained completely by removing the recoil.

Do not open the crankcase drain unless the engine has ingested water. On 4-cycle engines, some engine oil will be lost if crankcase drain is opened.

On the Trail Blazer, the recoil handle must be behind the heat shield for it to seal properly. If it is not sealed properly, water may entertherecoil housing anddamage components.

Recoil Drain

Crankcase Drain

Starter Pinion Drain

250 and 400 Engines

Counter Balance Drain (400s Only)

Recoil Drain (above front propshaft on shaft drive models)

Crankcase Drain

4-Cycle Engines

Page 63

STARTING THE ENGINE

Procedure for Starting a Cold Engine

1.Place the transmission in neutral and push the vehicle to a level surface.

2.Lock the parking brake.

3.Turn the fuel tank valve to ON.

4.Sit on the vehicle.

“HALF”

“FULL”

“OFF”

Choke Lever Top View

5.Move the choke lever to the FULL position.

6.Turn the ignition key to ON and the engine stop switch to RUN.

7.Press the starter button.

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

9.Pressstarterbutton for five seconds. If engine does notstart,release starterbutton and wait five seconds; then press starter button for another five seconds. Repeat this procedure until engine starts.

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

After the Engine Starts

1.Ifthe engine slows or stops, use of the choke lever at its HALF position will allow proper engine warm up.

2.Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly. Then move the choke to OFF.

CAUTION: Proper engine warm up is essential each time before driving to avoid engine damage.

WARNING

Carbon monoxide exhaust gas is poisonous! Always start the ATV outdoors. Never run the engine in an enclosed area.

Page 64

VEHICLE BREAK-IN PERIOD

2-Cycle Engines

The break in period for your new Polaris ATV is defined as the time it takes to use the first tank of gasoline. No single action on your part is as importantas a proper break in period. Careful treatment of a new engine will result in more efficient performanceandlongerlife for the engine. Perform the followingprocedurescarefully.

CAUTION: Use only Polaris injection oil. Never substitute or mix oil brands. Serious engine damage and voiding of warranty can result.

1.Mix12.8ounces of injectionoiltofour gallons (or 16 ouncesto5gallons)of gasoline in a suitablegas can. Fill the fuel tank as outlined on pages 47 through 48.

2.Fill the oil tank with Polaris injection oil.

3.Driveslowly at first. Select an area which is open and willgive you room to familiarize yourself with vehicle operation and handling.

4.Vary the throttle positions. CAUTION: Do not operate at full throttle or high speeds for extended periodsduringthefirstthree hours of use. Excessive heat can build up and cause damage to close fitted engine parts.

5.Perform regular checks on fluid levels, controls and all important areas on the vehicle as outlined earlier on the daily pre-ride inspection checklist found on page 14.

After the break in period the oil injection system provides the necessary engine lubricationwithout the need for pre-mixed fuel. CAUTION: To avoid serious engine damage always fill the oil tank when refueling the ATV.

After the first tank of pre-mixed fuel has been used please verify that the oil level in the 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.

Page 65

VEHICLE BREAK-IN PERIOD

4-Cycle Engines

The break in period for your new Polaris ATVis defined as the first ten hours of operation,or the time it takes to usethefirst two tanks fullof gasoline. No single action on your part is as important as a proper break in period. Careful treatmentof a new engine will result in more efficient performanceand longer life for the engine. Perform the following procedures carefully.

CAUTION: Use only Polaris Premium 4 All Season synthetic oil, or API certified “SH” oil. Never substitute or mix oil brands. Serious engine damage and voiding of warranty can result.

1.Fillfuel tank with either unleaded or leaded fuel which has a minimum pump octane number of 87= (R+ M)/2.

2.Check oil reservoir level indicated on dipstick. Add oil if necessary.

3.Drive slowly at first. Select an area which is open and will give you room to familiarize yourself with vehicle operation and handling.

4.Vary the throttle positions. Do not operate at sustained idle. CAUTION: Do not operateat full throttleor high speeds for extended periods during the firstthree hours of use. Excessive heat can build up and cause damage to close fitted engine parts.

5.Perform regular checks on fluid levels, controls and all important areas on the vehicle as outlined earlier on the daily pre-ride inspection checklist found on page 14.

6.Pull only light loads.

7.Break in oil and filter. Change at 20 hours or 500 miles.

ADD 8 OZ. NORMAL FULL

Maintain Oil Level In Normal Range

Page 66

RIDING GEAR

Safe Riding Gear

Always wear clothing suited to the type of ridingyou are doing. ATV riding requires special protective clothingwhich will make you feel more comfortable and reduce chances of injury.

1. Helmet

Your helmet is the most importantpiece of protective gear for safe riding. A helmet can prevent a serious head injury.

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

2. Eye Protection

Do not depend on sunglasses for proper eye protection. A pair of goggles or helmet face shield offer the best protection foryoureyes. They should be keptclean 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 type boots with heels, such as moto-cross boots.

5. Clothing

To protectyourbody, long sleeves and pants should alwaysbe worn. Ridingpants with kneepads, a jersey and shoulder pads provide the best protection.

Page 67

CARRYING LOADS

YourATV has been designed to carry a certainamount of load. CARGO WEIGHT should be evenly distributed (1/3 on the front and 2/3 on the rear) and mounted as low as possible. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions. Never exceed the weights specified in your Owner’s Manual Supplement.

Maximum trailer weight - 850 lbs.(386 kg); maximum vertical hitch weight - 30 lbs.(14 kg). Selectmodelsmay tow up to 1250 (568 kg) on level ground only. Refer to your Owner’s Manual Supplement to determine your machine’s capabilities. IMPORTANT: Know your machine before your ride.

Maximumgradewhile trailertowing -15°. Do not tow any trailer on a gradesteeper than 15°.

If your machine is equipped with a front rack, take care when loading. Improper loading of the front rack can obstruct the headlight beam, reducing night visibility. Do not obstruct the headlight beam with cargo.

Use of low forward gear is recommendedin heavy pulling situationsto extend belt life.

Page 68

CARGO WEIGHT DISTRIBUTION

2/3 of Load on Rear Rack

1/3 of Load on Front Rack

WARNING

Correct loading of this vehicle is necessary to maintain proper stability and operating characteristics. Overloading or incorrectpositioningof the load affects the vehicle’s turning, stopping distance and stability. Failure to follow loading requirements could cause severe injury or death. REDUCE SPEED AND ALLOW GREATER DISTANCE FOR BRAKING WHEN CARRYING CARGO.

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 tip over.

HEAVYLOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations which may require backing downhill.

ALL LOADS MUST BE SECURED BEFORE MOVING VEHICLE. Unsecured loads can create unstable operating conditions, which could result in loss of control of the vehicle.

LOADS MUST BE CARRIED AS LOW ON THE RACKS ASPOSSIBLE. Carrying loads high on the racks raises the center of gravity of the vehicle and creates a less stableoperating condition. When cargo loads are carried high on the racks, the weight of theloads must be reduced tomaintainstableoperating conditions.

OPERATEONLY WITH STABLE AND SAFELY ARRANGED LOADS. When handling off-centered loads which cannot be centered, securely fasten load and operate with extra caution. Always attach the tow load to the hitch point designated for your ATV.

EXTREME CAUTION MUST BE USED when operating with loads extending overthe rack sides. Stability and maneuverability may be adversely affected, causing the machine to overturn.

DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the front rack.

DO NOT TRAVELFASTERTHANTHERECOMMENDEDSPEEDS. 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.

Page 69

DAILY PRE-RIDE INSPECTION

Inspect your ATV each time before riding to ensure it is in proper working order. If proper inspection is not done, severe injury or death could result.

WARNING

Item/Inspection Procedure

1.Tires - check condition and pressures

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

3.All brakes -check operation, adjustment and fluid level (includes auxiliary brake)

4.Throttle - check for free operation and closing

5.Headlight/Taillight/Brakelight - check operation of all indicator lights and switches

6.Engine stop switch - check for proper function

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

8.Drive chain - condition and slack; refer to drive chain adjustment

9.Air cleaner element - check for dirt; clean or replace

10.Steering - check for free operation noting any unusual looseness in any area

11.Loose parts- visually inspect vehicle for any damaged or loose nuts/ bolts or fasteners

12.Operators helmet, goggles and clothing

13.Engine coolant - (Liquid Cooled Models Only) check for proper level at the recovery bottle

Page 70

RIDING

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

2.After starting the engine and allowing it to warm up, 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 and all transmission shifting is done automatically.

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

indicates a potential hazard which couldresultinseriousinjuryor death.

WARNING

Page 71

RIDING

Making Turns

Practice making turns at slow speeds.

Polaris ATVs are equipped with a solid rear axle which drives both rear wheels equallyatalltimes. Thismeans that the wheel on the outside of the turnmusttravel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly. To turn, steer in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. This technique alters the balance of traction between the rear wheels allowing the turn to be made smoothly. The same leaning technique should be used for turning in reverse. WARNING: Avoid turning at sharp angles in reverse as tipover and serious injury may result.

indicates a potential hazard which couldresultinseriousinjuryor death.

WARNING

Page 72

RIDING

Riding On Slippery Surfaces

Whenever riding on slippery surfaces such as wet trails or loose gravel, or during cold freezing weather, special attention must be paid to prevent vehicle turnover. Always:

1.Slow down when entering s lippery 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.

4.DrivingwithDemand 4 Drive (All Wheel Drive) engaged can assist in controlling the vehicle in slippery areas. CAUTION: Never engage Demand Drive while wheels are spinning as severe damage to drive train may occur.

WARNING

Failure to exercise care when operating the ATV on slippery surfaces can be dangerous.

Loss of tire traction and vehicle control can result in an accident, including an overturn.

DNever apply brakes during a skid. Complete loss of ATV control can

result.

DDo not operate on excessively slippery surfaces if possible to avoid. DAlways reduce speed and use additional caution.

Page 73

RIDING

Traveling Uphill

25_ Maximum

Whenever traveling uphill always travel straight uphill and:

1.Avoid steep hills.

2.Keep both feet on the footrests.

3.Transfer your weight forward.

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

5.Remainalertand be preparedtotake emergency action. This may includequick dismounting of the ATV.

WARNING

Braking and handling are greatly affected whenever operating in hilly terrain.

Loss of vehicle control or overturning of the ATV could occur.

DAvoid operating on steep hills (25_ maximum). DUse extreme care when operating your ATV in hilly terrain.

indicates a potential hazard which couldresultinseriousinjuryor death.

WARNING

Page 74

RIDING

Sidehilling

Sidehilling your ATV is one of the most dangerous types of riding and should be avoided if possible. In the event you do enter into a situation where sidehilling is necessary, always:

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.

If vehicle begins to tip,quicklyturnthefrontwheeldownhill, if possible, or dismount on the uphill side immediately!

WARNING

Improperly crossing hills or turning on hills can be dangerous! Loss of vehicle control or overturning of the ATV could occur.

DAvoid crossing the side of a steep hill if possible. DUse extreme care when operating your ATV in hilly terrain.

Page 75

RIDING

Traveling Downhill

Whenever descending a hill, always:

1.Drive directly downhill.

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

3.Slow down.

4.Apply the brakes slightly to aid in slowing.

Familiarize yourself with the auxiliary rear brake pedal and itsuse in the event loss of normal service brakes occurs.

WARNING

Loss of vehicle controldue to excessive speed can occur. Loss of control may result in serious injury or death.

Page 76

RIDING

Turning Around On A Hill

8’

Uphill

If the ATV stalls while climbing a hill, never back it down thehill! One maneuver which can be used when it is necessary to turn around while climbing a hill is the K-turn.

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

2.Leave transmission in forward and shut off engine.

3.Dismount on left or uphill side of ATV.

4.Staying uphill of ATV, turn handlebars full left (while facing front of ATV).

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

6.Lock the parking brake and remount ATV from the uphillside, maintaining body weight uphill.

7.Restartenginewith transmissionstillin forward,releaseparking brake, and proceed slowly, controlling speed with the s ervice brake, until ATV is on reasonably level ground.

WARNING

Avoid climbing steep hills. Loss of vehicle control or overturning of the ATV could occur. DUse extreme care when operating your ATV in hilly terrain.

Page 77

RIDING

Crossing Streams

Your Polaris ATV can operate through water up to depths reaching the footrests. Before fording streams always:

1.Determine water depths and current.

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

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

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

CAUTION: Should your ATV become immersed, it will be necessary to take it to your dealer as soon as possible. Do not start the engine! Immersion of the ATV can cause major damage if not correctly repaired.

WARNING

Never try to cross any deep or fast flowing streams. The large tires can cause the ATV to float resulting in loss of control. DDetermine stream depth and speed before crossing.

Page 78

RIDING

Trail Obstacles

Keep Alert!

Look ahead and learn to read the trail as you ride. Stay on the right side of the trail, ifpossible,and be constantly alertforhazards such as logs,rocksand low hanging branches.

WARNING

Hidden or unseen hazards on the trail can be dangerous. Personal injury or the vehicle overturning can occur from unseen obstacles. DKeep alert and constantly look for obstacles on the trail.

indicates a potential hazard which couldresultinseriousinjuryor death.

WARNING

Page 79

RIDING

Backing Up

1.Whenever backing up, 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.

6.Never activate override button while throttleis open. Loss of control may result.

NOTE: This vehicle is equipped with a reverse speed limiter. The overridebutton should be used with caution as rearward vehicle speed is greatly increased. Do not operate at wide open throttle. Only open the throttle enough to maintain a desired speed. Opening the throttle more than required may cause excessive fuel to build in the exhaust, resulting in engine popping and/or engine damage.

WARNING

Backing your ATV can be dangerous! You could hit an obstacle or person behind you; or the ATV could tip over rearward on a steep incline.

DAlways back slowly, avoiding excessive speed; and do not use the

reverse s peed override switch system unless additional power is required for vehicle movement.

DAvoid backing on steep inclines.

Page 80

RIDING

ParkingonanIncline

Whenever the Vehicle is Parked

1.Turn the engine off.

2.Place the transmission in gear.

3.Set the parking brake.

4.Avoid parking on an incline. If it is necessary to park on an incline, always block the rear wheels on the down hill side as shown above.

5.Shut off fuel supply.

indicates a potential hazard which couldresultinseriousinjuryor death.

WARNING

Page 81

BATTERY

Battery

CAUTION

Whenever removing the battery, disconnect the negative (black) cable first. When reinstalling the battery, connect the negative (black) cable last.

Replenishing the Battery Fluid

A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. The fluid level should be kept between the upper and lower level marks.

To refill use only distilled water. Tap water contains minerals which are harmful to a battery.

Battery Connections

Battery terminals and connections should be kept free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with

a solution of one tablespoon baking soda and one cup water. Rinse well with tap waterand dry offwithcleanrags. Coat the terminalswith dielectric grease or petroleum jelly.

Do not allow cleaningsolutionor tap water to enter the battery. It will shorten

the life of the battery .

WARNING

Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote:

External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia,

beaten egg, or vegetable oil. Call physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away.

Ventilate when charging or using in an enclosed space. Always shield eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN.

Maintain between upper and lower level marks

Page 82

BATTERY

Battery Removal

1.Disconnect hold down straps holding the electrical box and battery in position and remove battery cover.

2.Remove the battery vent tube from the battery.

3.Disconnect the black (negative) battery cable first.

4.Disconnect the red (positive) battery cable next.

5.Lift the battery out of the ATV, being careful not to tip it sideways and spill any electrolyte.

CAUTION: If electrolyte spills, immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the ATV.

Battery Installation

WARNING: To avoid the possibility of explosion, always connect battery cables

in the order specified. Red (positive) cable first; black (negative) cable last.

1.Set the battery in its holder.

2.Install the battery vent tube. It must be free from obstructions and securely installed. If not, battery gases could accumulate and cause an explosion. The tube should be routed away from the frame and body to prevent corrosion. Avoid skin contact with electrolyte, severe burns could result.

3.First connect and tighten the red (positive) cable.

4.Second connect and tighten the black (negative) cable.

5.Reinstall battery cover and attach the hold down strap.

6.Verify that cables are properly routed.

NOTE:

DWhen your ATV is placed in storage for three months or more, the battery

should be removed, charged to proper level, and stored in a cool dry place.

DBefore reusing, take the battery to your dealer for testing and recharging. DPower plug leads may need to be bent down so that the battery cover may be

installed.

Page 83

NOISE EMISSION CONTROL SYSTEM REGULATION

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED! U.S. Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperativeby any person other thanfor purposes of

maintenance, repair, or replacement of any device or element of design incorporatedintoanynew vehicle forthepurposeofnoisecontrolprior to itssaleordelivery to the ultimate purchaser or while it is in use or

(2)the use ofthe vehicle after such device orelementof design has been removed or rendered inoperative by any person.

“AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW.”

1.Removal or alteration or the puncturing of the muffler or any engine component which conducts removal of engine exhaust gases.

2.Removal or alteration or the puncturing of any part of the engine air induction system.

3.Replacementof any vehicle partswith parts not in compliance with federalregulations.

4.Lack of proper maintenance.

CAUTION: Remember,exhaust system components are very hot during and after use of ATV.

DDo not touch exhaust system components. Serious burns can result. DBe especially careful when traveling through tall grass. The potential for fire

exists.

USFS Approved Spark Arrestor

MostPolaris ATVs have mufflersthatwere tested and approved in accordance with theUSFS Forest ServiceStandard5100-1A. For specific information on yourmodel, see the Owner’s Manual Specification Supplement that came with your machine.

Page 84

MAINTENANCE

Spark Arrestor

The exhaust pipe must be periodically purged of accumulated carbon as follows:

1.Remove the clean out plugs located on the bottomofthe muffler as shown above.

2.Place the transmission in neutral and start the engine. Purge accumulated carbon from the system by momentarily revving the engine several times.

3.If some carbon is expelled, cover the exhaust outlet and rap on the pipe around the clean out plugs while revving the engine several more times.

4.If particlesare still suspected to be in themuffler, back the machine onto an incline so the rear of the machine is one foot higher than the front. Set the parking brake and block the wheels. Make sure the machine is in neutral and repeat steps 2 and 3. WARNING: SEE BELOW.

5.If particlesare still suspected to be in the muffler, drive the machine onto the incline so the front of the machine is one foot higher than the rear. Set the parking brake and block the wheels. Make sure the machine is in neutral and repeat steps 2 and 3. WARNING: SEE BELOW.

6.Repeat steps 2 through 5 until no more particles are expelled when the engine is revved.

7.Stop the engine and allow the arrestor to cool.

8.Reinstall the arrestor plugs.

Clean Out Plugs

Clean Out Plug

Page 85

MAINTENANCE

Spark Arrestor (Cont.)

WARNING

DDo not perform this operation immediately after the engine has been run

because the exhaust system becomes very hot.

DBecause of the increased fire hazard, make sure that there are no com-

bustible materials in the area when purging the spark arrestor.

DWear eye protection. DDo not stand behind or in front of the vehicle while purging the carbon

from the spark arrestor.

DNever run the engine in an enclosed area. The exhaust contains poi-

sonous carbon monoxide gas.

DDo not go under the machine while it is inclined. Failure to heed these warnings could result in serious personal injury or death.

CAUTION: Keep combustible materials away fromexhaust system. Fire may result.

Page 86

MAINTENANCE

Tool Kits

To help you perform routine maintenance, a tool kit is provided in the storage compartment under the seat. Items included in the kits are:

2-cycle engines

Dflat screwdriver Dspark plug wrench with Phillips head screwdriver Dwrench Dtire pressure gauge Dspanner wrench for adjusting rear shock spring preload (selected models)

4-cycle engines

Dscrewdriver Dopen end wrench (8-10 mm) Dopen end wrench (12-14 mm) Dbox end wrench Dtire pressure gauge Dspark plug wrench and handle Dspanner wrench for adjusting rear shock spring preload (selected models)

NOTE: Other tools are also necessary to perform maintenance work. They are called out later in this manual.

Power Pig Tail

Some models are equipped with an auxiliary power outlet. Refer to your Owner’s Manual Supplementto determine if your machine has one.

CAUTION: Be sure to wrap bare wires with electrical tape and follow correct wire splicing procedures to avoid shorts in the wiring system.

The power outlet and pigtail may be purchased from Polaris using the following numbers: outlet - 2410022; pigtail 2460442

Power Outlet 2410022

Pigtail 2460442

Rear Mounted Power Outlet

Page 87

MAINTENANCE

Periodic Maintenance Schedule

Careful periodic maintenance will help keep your vehicleinthesafest,most reliable condition. Inspection, adjustment and lubrication intervals of important components are explained in the following chart

Maintenance intervals are based upon average riding conditions and a vehicle speed of approximately 10 milesper hour. Vehicles subjected to severe use, such as operation in wet or dusty areas, should be inspected and serviced more frequently. If you are not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

Inspect, clean, lubricate,adjust or replace parts as necessary. NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts available from your Polaris dealer.

Service and adjustments are critical. If you are not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

J CAUTION: Due to the nature of these adjustments, it is recommended that service be performed by an authorized Polaris dealer. Do not attempt to perform this work unless you are familiar with mechanical repair.

" More often under severe use, such as dirty or wet conditions L Emission ControlSystemService (California - 4-Cycle) NOTE: Some 4-Cycle

models may have an additional California -only emissions warranty. Please refer to your owner’s manual supplement to determine if this applies to your vehicle.

Item Hours or

Odometer

Frequency Remarks

Brake System Pre-ride Pre-ride Pre-ride inspection item

Auxiliary Brake Pre-ride Pre-ri de Pre-ride inspection item

Tire s Pre-ride Pre-ri de Inspect daily, pre-ride inspection item

Wheels Pre-ride Pre-ri de Pre-ride inspection item

Frame nuts, bol ts, fasteners Pre-ride Pre-ride Pre-ride inspection item

Injector Oil Level (2-Cycle) Daily Daily Check when refueling

Air Filter - Pre-Cleaner Daily Daily Inspect-Clean

Coolant/Level Inspec tion Daily Daily Replace engine coolant every two

years

" Air Box Sediment Tube Daily Daily Drain deposits whenever visi bl e

Headlamp Inspection Daily Daily Check operation daily; apply Polaris di-

electric grease to connector when replaced

Tail lamp inspection Daily Daily Check operation daily; apply Polaris di-

electric grease to sock et when replaced

AirFilter-MainElement Weekly Weekly Ins pect-Replace if necessary

" Transmission Oil Level 25 hrs Monthly Inspect monthly; change annually

Battery 20 hrs Monthly Check Terminals/clean/check fluid lev el

Engine Counterbalance (400 Engines)

20 hrs Monthly Check oi l level; change annually

Page 88

MAINTENANCE

Periodic Maintenance Schedule (Cont.)

Item Hours or

Odometer

Frequency Remarks

Engine breather filter (4-cycle)

20 hrs Monthly Inspect--replace annually and as need-

J Brake pad wear 10 hrs/100

miles

Monthly Inspect periodical ly

" Front and Rear Gearcase Oil

(shaft drive)

100 hrs Monthly Check monthly and change annually

Engine Cylinder Head and Cylinder Base Fasteners

25 hrs 3 months Inspect (re-torque required at first s er-

vice only)

" General Lubrication 50 hrs 3 months Lubricate all fittings, piv ots , cables, etc.

Engine Oil - Level/Change (4-Cycle)

100 hrs/1000 miles

6 months Check Level Daily; Break in Service at

1 month. Change oil more often in cold weather use.

Oil Filter(4-Cyc le) 100 hrs/1000

miles

6 months Replace with oil change

Oil Pump Cable (2-Cycle) 50 hrs 6 months Inspect, adjust, lubricate, replace if re-

quired

Engine breather hose (4-cycle)

100 hrs 6 months Inspect

Carburetor Float Bowl 50 hrs 6 months Drain bowl periodical ly and prior to stor-

age

J Throttle Cable/ETC Switch 50 hrs 6 months Inspect--adjust, lubricate, replace if nec-

essary; pre-ride inspection item

Choke (Enricher) Cabl e 50 hrs 6 months Inspect--adj us t, lubricate, replac e if nec -

essary

Coolant strength/pressure test system

100 hrs 6 months Inspect strength seasonally; pressure

test system annually

" Front hubs/fluid chec k (AWD) 50 hrs 6 months Chec k monthly

Shift linkage 50 hrs 6 months Inspect, adjust

J Drive belt 50 hrs 6 months Ins pec t, replace i f necessary

J Steering 50 hrs 6 months Ins pec t daily, lubricate

" Rear Axle 50 hrs 6 months Inspec t bearings, Lube

" Front Suspension 50 hrs 6 months Inspect --lubricate, ti ghten fasteners

" Rear Suspension 50 hrs 6 months Inspect, tighten fasteners

" Drive Chain(s) 50 hrs 6 months Inspect daily, adjust and lubricate if

needed

Spark Plug 100 hrs 12 months Inspect--replace if necessary

Ignition Timing 100 hrs 12 months Inspect and adjust as needed

Fuel System 100 hours 12 months Check for leaks at tank cap, lines, fuel

valve, fil ter, pump and c arburetor. Replace lines every two years.

J Fuel Filter 100 hrs 12 months Replace annually

Radiator 100 hrs 12 months Inspect/clean external surface

Cooling Sys tem hoses 100 hrs 12 months Inspect

Spark arrestor 100 hrs 12 months Clean out

Page 89

MAINTENANCE

Periodic Maintenance Schedule (Cont.)

Item Hours or

Odometer

Frequency Remarks

" Front hubs/fluid change (AWD) 100 hrs 12 months

J Clutches (drive and driven) 100 hrs 12 months Inspect, clean

Engine Mounts 100 hrs 12 months Inspect

Valve Clearance (4-Cycle) 100 hrs 12 months Inspect/Adjus t

Spark Plug 100 hrs 12 months Inspect--replace if necessary

Ignition Timing 100 hrs 12 months Inspect and adjust as needed

J Fuel Filter 100 hrs 12 months Replace annually

Radiator 100 hrs 12 months Inspect/clean external surface

Cooling Sys tem hoses 100 hrs 12 months Inspect

Spark arrestor 100 hrs 12 months Clean out

" Front hubs/fluid change (AWD) 100 hrs 12 months

J Clutches (drive and driven) 100 hrs 12 months Inspect, clean

Fuel System 100 hours 12 months Check for leaks at tank cap, lines, fuel

valve, fil ter, pump and c arburetor. Replace lines every two years.

J Injector Oil Filter (2-Cycle) 100 hrs A nnual ly Replace

J Shift selector box (H/L/R) 200 hrs 24 months Change lubricant every two years

J Brake fluid 200 hrs 24 months Change every two years

J Front wheel bearings (2wd) 300 hrs 36 months Inspect, replace if necessary

Idle Speed As Required As Required Adjust

Recoil housing As required As required Drain moisture out after riding in water

J Toeadj ustment As required As required Periodic inspection, adjust when parts

are replaced

Headlight Aim As required As required Adjust if necessary

" More often under severe use, such as dirty or wet conditions L Emission Control System Service (California - 4-Cycle)

NOTE: Some 4-Cycle models may have an additional California -only emissions warranty. Please refer to your owner’s manual supplement to determineif this applies to your vehicle.

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MAINTENANCE

Lubrication Recommendations

Item Lube Rec. Method Frequency*

1. Engine Oil (2-Cycle)

Polaris Injection Oil

Fill oil tank. See page 47. As needed,

when refueling

2.Engine Oil (4-Cycle)

Polaris Premium 4 Synthetic 0W40

Add to proper level on dipstick. See page 49.

Check level daily.

3. Brake Fluid DOT 3 Only Maintain level between fill lines. See page 39.

As required; change every two years or 200 hours

4. Transmission

Oil

Polaris Premium Synthetic gear case lube

Add to FULL level on dipstick or fill to bottom of the filler hole, whichever is applicable.

Change annually or at 100 hours

5. Front Gear-

case Oil

GL 80-90 Weight Gear Lube

Fill to bottom thread of filler hole. Make certain machine is on level surface.

Change annually or at 100 hours

6. Front Prop

Shaft U-joints

Grease+ Locate Fittings and Grease Every 3 months

or 50 hours

7. Front Prop-

shaft Yoke

Grease+ Locate fittings and grease -- 3

pumps maximum

Every 3 months or 50 hours

8. Drive Chain(s) O-Ring chain

lube or SAE 80/90

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

As required

9. Demand 4

Hubs - All Wheel Drive ATVs

Premium Hub Lube

Remove set screw in hubs. Rotate wheels to 4 O’clock position. If lubricant is not visible add more. Reinstall set screw.

Annually or at 100 hrs

10. Front Drive

Axle (U Joint) (AWD Mod els)

Grease+ Locate grease fitting and grease

with grease gun.

Every 3 months or 50 hours

11. Ball Joint Grease** Locate fitting on back side of struts and grease with grease gun.

Every 3 months or 50 hours

12. Rear Gear

Case

GL 80-90 Weight Gear Lube

Fill to bottom of the fill hole. Change annually

or at 100 hours

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MAINTENANCE

Lubrication Recommendations

13. Front A Arm Pivot Shaft

Grease**∆ Locate fitting on pivot shaft and

grease with grease gun.

Every 3 months or 50 hours

14. Counter Bal-

ance Housing (400)

SAE 10/30 Check level on dipstick and add oil as

necessary. Change annually. To change oil see page 108.

Check monthly and change annually

15. Steering Post Bushings

Grease** Locate fittings on steering post and

grease with grease gun.

Every 3 months or 50 hours

16. Rear Axle Bearing

Grease** Locate fittings and grease Every 3

months or 50 hours

17. Swing Arm Bushings

Grease** Locate fittings on swing arm and

grease with grease gun.

Monthly or at 20 hours

18. Upper Control

Arms

Grease**∆ Locate fittings and grease Semi-annually

19. Lower Control

Arms

Grease**∆ Locate fittings and grease Semi-annually

20. Rear Wheel

Hub Bearing Carrier

Grease**∆ Locate fitting and grease Semi-annually

21. Rear Anti-Roll

Bar

Grease Locate fitting and grease Semi-annually

* More often under severe use, such as wet or dusty conditions. **Polaris Premium all Season Grease or grease conforming to NLGI No. 2, such as Conoco Superlube M or Mobilegrease Special. + Grease every 500 miles, or after submerging in water or before long periods of storage or after pressure washing. Always use Polaris Premium U-Joint Lube for maximum service of these driveline components (PN 2871515 3 oz.)(PN 2871551 14 oz.). ∆ When suspension action becomes stiff or after washing. NOTE: Hours are based on 10 mph average.

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MAINTENANCE

Lubrication Recommendations

Operating Range

Full

4. Transmission (dipstick)

6. Front Prop Shaft (U-Joint)

10. Axle Cardan Front Drive (AWD Models)

7. Propshaft Yoke

Fill plug

5. Front Gear Case

14. Counterbalance Dipstick

4. Transmission (plug)

12. Rear Gear Case - Fill Hole

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MAINTENANCE

Lubrication Recommendations

15. Steering Post Bushings

11. Ball Joint

13. Front A-Arm Pivot Shaft

Lower

Upper

9. 4 O’clock position

9. Demand 4 Hubs (4x4 only)

Page 94

MAINTENANCE

Lubrication Recommendations

17. Swing Arm Bushings

16. Rear Axle Bearing

18. Upper Control Arm

20. Rear Wheel Hub Bearing Carrier

21. Rear AntiRoll Bar

19. Lower Control Arm

INDEPENDENT REAR SUSPENSION

19. Lower Control Arm

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MAINTENANCE

Periodic Maintenance Record

Use the following chart to record periodic maintenance work:

Maintenance

Interval

Performed

Servicing

Date

Servicing

Dealer

or Person

Remarks

First 5 Hrs.

25 Hrs. 50 Hrs. 75 Hrs.

100 Hrs.

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MAINTENANCE

Steering

Handlebar Adjustment

Your ATV has handlebars which can be adjusted for your personal fit.

1.Locate handlebar bolts. On models with a headlight pod, it will be necessary to remove the upper headlight pod. On other models remove the handlebar cover.

2.Loosen the four bolts.

3.Adjusthandlebarto desiredheight. Be sure handlebars do not hit gas tank or any other part of machine when turned fully to left or right.

4.Torque handlebar adjuster block bolts to 10 to 12 ft. lbs.

NOTE: Tighten bolts so there is an equal gap at the front and rear of the handlebar block. Improper gap will result in improper fit of upper pod.

WARNING

Improper adjustment of the handlebars or incorrect torquing of the adjuster block tighteningbolts can causelimitedsteering or loosening of the handlebars, resulting in loss of control and possible serious personal injury or death.

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MAINTENANCE

The following items should be checked occasionally for tightness; or if they have been loosened for maintenance service.

Axle and Wheel Nut Torque Specifications

Model Item Specification

Front Spindle Nut(s) 40 Ft. Lbs.

2X4

Front Wheel Nuts 15 Ft. Lbs.

2X4

Rear Axle Nut(s) 80 Ft. Lbs.

Rear Wheel Nuts 50 Ft. Lbs.

Front Spindle Nut(s) Dealer Performed Service

4x4

Front Wheel Nuts 15 Ft. Lbs.

4x4

Chain Drive

Rear Axle Nut(s) 80 Ft. Lbs.

Rear Wheel Nuts 50 Ft. Lbs.

Front Spindle Nut(s) Dealer Performed Service

4x4

Front Wheel Nuts 15 Ft. Lbs.

4x4

Shaft Drive

Rear Hub Retaining Nut(s) 100 Ft. Lbs.

Rear Wheel Nuts 50 Ft. Lbs.

Front Wheel Hub Tightening

Frontwheel bearing tightness and spindle nut retention are critical component operations. Service work must be performed by your authorized Polaris dealer.

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MAINTENANCE

Rear Spring Adjustment

The rear shock absorber spring is adjustedby rotating the adjusterin the direction required to increase or decrease spring tension.

Rear Spring Adjustment Cam

Rear Spring Adjustment

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MAINTENANCE

Side Panel Removal (Gen IV Models)

Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times.

1. Remove seat. Grasp rear ofside panel near rearcab. With a quick and firm motion, pull the panel forward and outward to disengage the two rear tabs.

2. Place hand on top of side panel behind the fuel tank. With a quick and firm motion, push down on the side panel to disengage thetop rear two tabs. Then pull up on side panel to disengage front upper and lower tab.

3. To reinstall side panel, align panel tabs with slots on front cab. Push panel upward and forward until tabs lock. Bend rear of side panel and insert the two tabs into the rear cab.

Pull forward and out to disengage two rear tabs.

Step 1.

Push down to disengage top rear two tabs.

Step 2.

To reinstall, align panel tabs with slots. Push upward and forward until tabs lock.

Step 3.

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MAINTENANCE

Air Cleaner Trail Blazer

Secondary (Main) Filter

Inspect the secondary filter weekly or after every 50 hours of operation. CAUTION: Never operate the ATV with the filter element removed. Dirt will enter

the engine causing serious rapid wear and damage to the engine.

Secondary filter removal and installation procedure:

1.Remove ATV seat.

2.Remove primary air filter box.

3.Removefourwingnutsholdingcover assembly to secondary air filter housing.

4.Remove filter element.

5.Inspect gaskets on both sides of filter. Replace if required.

6.Coat top and bottom gaskets of filter with a generous amount of grease.

7.Check condition of air box and replace if necessary. Install filter into airbox. Be sure filter element seats securely.

8.Check cover gasket and replace if required. Be sure cover is seated properly and wing nuts are finger tightened securely.

9.Reinstall primary air filter box as per instructions found on page 93.

10.Reinstall ATV seat.

Cleaning the Main Filter

Important:

It is advisable to replace the filter when it is dirty. However, in an emergency it is permissible to clean the main filter if you observe the following practices.

1.Never immerse the filter in water since dirtcan be transferredtothecleanairside of the filter.

2.Ifcompressed air is used never exceed a pressure of 40 PSI. Always use a dispersion type nozzle to prevent filter damage and clean from the outside to the inside.

NOTE: Replace the air filter every 50 hours, and possibly more often in very dirty conditions.