Polaris UTV Series 10 2x4, UTV Series 10 4x4 Owner's Manual

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Page 1

Page 2

WARNING

The engine exhaust from this

product contains chemicals known

to cause cancer, birth defects or

other reproductive harm.

Page 3

Page 4

-NOTES-

Page 5

WELCOME

Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris enthusiasts. Polaris proudly produces an exciting line of recreational products, including snowmobiles, all-terrain vehicles, personal watercraft, utility vehicles, and Victory motorcycles.

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

Follow the instructions and recommendations in this Owner ’s Manual for safe and enjoyable operation of your vehicle. Your Owner’s Manual contains instructions for minor maintenance, but major repairs are covered in the Polaris Service Manual and should be performed by a Factory Certified Master Service Dealer (MSD) Technician.

Your Polaris UTV dealer knows your vehicle best and is interested in your complete satisfaction. Return to your dealership for all of your service needs during, and after, the warranty period.

Polaris also takes great pride in our PAA (Parts Apparel and Accessories) which are available in our online store at www.purepolaris.com. Have your accessories and clothing delivered right to your door!

Polaris and Polaris The Way Out are registered trademarks of Polaris Industries Inc.

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THIS VEHICLE IS NOT A TOY AND CAN BE

HAZARDOUS TO OPERATE. This vehicle 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:

n Read this manual and all labels carefully. Follow the operating

procedures described.

n Never allow anyone without a valid driver’s license to operate this

vehicle.

n Minimum age recommendation for passengers is five years old.

Passengers under five years of age require special restraints which are not available with this vehicle. Driver and passenger should wear their seat belts at all times.

n Never permit a guest to operate this vehicle unless the guest has

read this manual and all product labels.

n To reduce tipover risk, be especially careful when encountering

obstacles and slopes and when braking on hills or during turns.

n Always fasten your seat belts securely around you.

n This vehicle is for off road use only. Never operate on public

roads. Always avoid paved surfaces.

n Helmets are recommended whenever driving this vehicle in an

aggressive manner. Eye protection is recommended at all times.

n Never consume alcohol or drugs before or while operating this

vehicle.

n Never operate at excessive speeds. Always travel at a speed proper

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

n Never attempt wheelies, jumps or other stunts.

n Always inspect your vehicle each time you use it to make sure it’s

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

n Always keep both hands on the steering wheel and both feet on the

floorboards of the vehicle during operation.

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n Always travel slowly and use extra caution when operating on

unfamiliar terrain. Be alert to changing terrain.

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

n Always follow proper procedures for turning as described in this

manual. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speeds.

n Always have this vehicle checked by an authorized Polaris dealer if

it has been involved in an accident.

n Never operate this vehicle on hills too steep for the vehicle or for

your abilities. Practice on smaller hills before attempting larger hills.

n Always follow proper procedures for climbing hills as described in

this manual. Check the terrain carefully before attempting to climb a hill. Never climb hills with excessively slippery or loose surfaces. Never open the throttle suddenly or make sudden gear changes. Never go over the top of a hill at high speed.

n Always follow the proper procedures outlined in this manual for

traveling downhill and for braking on hills. Check the terrain carefully before descending a hill. Never travel downhill at high speed. Avoid going downhill at an angle, which would cause the vehicle to lean sharply to one side. Travel straight down the hill where possible.

n Always follow proper procedures for crossing the side of a hill as

described in this manual. Avoid hills with excessively slippery or loose surfaces. Never attempt to turn the vehicle around on any hill until you have mastered (on level ground) the turning technique described in this manual. Avoid crossing the side of a steep hill if possible.

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

attempt to operate over lar ge obstacles such as rocks or fallen trees. Always follow the proper procedures outlined in this manual when operating over obstacles.

n Always be careful of skidding or sliding. On slippery surfaces

such as ice, travel slowly and exercise caution to reduce the chance of skidding or sliding out of control.

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n Never operate your vehicle in fast-flowing water or in water deeper

than that specified in this manual. 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.

n Always be sure there are no obstacles or people behind your

vehicle when operating in reverse. When it’s safe to proceed in reverse, move slowly. Avoid turning at sharp angles in reverse.

n Always use the proper size and type of tires specified in this

manual. Always maintain proper tire pressure as specified on page

97.

n Never modify this vehicle through improper installation or use of

accessories.

n Never exceed the stated load capacity for this vehicle. Cargo

should be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for hauling cargo or pulling a trailer. Allow a greater distance for braking.

n Always wear the seat belts when operating this vehicle. Seat belts

reduce the severity of injury in case of a sudden stop or collision.

n Always keep arms and legs inside the cab frame while the vehicle

is in motion.

n Always apply the parking brake before getting out of the vehicle.

Seepage46.

n Always activate the foot pedal brake before releasing the park

brake.

n Always turn off the engine before refueling. Make sure the

refueling area is well ventilated and free of any source of flame or sparks. Gasoline is extremely flammable. See page 54 for refueling instructions.

FOR MORE INFORMATION ABOUT SAFETY, call Polaris at 1-800-342-3764.

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Additional Important Information

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

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

We also advise you to strictly follow the recommended maintenance program outlined in this manual. This preventive maintenance program is designed to ensure that all critical components on the vehicle 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 vehicle.

Be sure any accessories added to this vehicle have been approved by Polaris, and familiarize yourself with their function and effect on the vehicle.

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-NOTES-

Page 11

TABLE OF CONTENTS

Vehicle Identification Numbers 11.............

Safety 12....................................

Features and Controls 36.....................

Operation 47.................................

Noise Emission 55...........................

Maintenance and Lubrication 56...............

Specifications 96.............................

Troubleshooting 98..........................

Warranty 100................................

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-NOTES-

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VEHICLE IDENTIFICATION NUMBERS

Important: Record your vehicle’s identification numbers in the spaces provided.

Frame VIN:

Engine Serial Number (right front side of engine crankcase)

NOTE: Remove the spare key and store in a safe place.

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

Vehicle Model Number:

Dealer Imprint

VIN

Page 14

SAFETY

Operator Safety

The following signal words and symbols appear throughout this manual and on your UTV. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual.

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

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

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

CAUTION

NOTE

A note will alert you to important information or instructions.

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

CAUTION

WARNING

Page 15

SAFETY

Operator Safety

WARNING

Driving a UTV requires your full attention. DO NOT drink alcohol or use drugs or medications before or while driving. They will reduce your alertness and slow your reaction time. In most states and provinces, it’s prohibited by law to drive while intoxicated or under the influence of drugs.

Make sure your UTV is in excellent operating condition at all times. We strongly recommend that the operator check all safety components before each ride.

Polaris UTVs are designed to provide safe operation when used as directed. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power. DO NOT MODIFY YOUR MACHINE. The UTV may become aerodynamically unstable at speeds higher than those for which it is designed. Loss of control may occur at higher speeds. Modifications may also create a safety hazard and lead to bodily injury .

The warranty on your entire machine is terminated if any equipment has been added, or any modifications have been made, to increase the speed or power of the UTV.

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SAFETY

Operator Safety

POTENTIAL HAZARD Stalling, rolling backwards while climbing a hill WHAT CAN HAPPEN Vehicle overturn HOW TO AVOID THE HAZARD Maintain a steady speed when climbing a hill. Ifyouloseallforwardspeed: Apply the brakes. Lock the parking brake after when fully stopped. If you begin rolling

backwards: Never apply engine power. Apply the brake gradually. When fully stopped, lock parking brake. In the event of an accident, have a qualified service dealer check

the complete machine for possible damage, including (but not limited to) brakes, throttle and steering.

WARNING

Page 17

SAFETY

Operator Safety

POTENTIAL HAZARD Operating this vehicle on paved surfaces WHAT CAN HAPPEN Loss of control HOW TO AVOID THE HAZARD This vehicle’ s tires are designed for off-road use only, not

for use on pavement. Paved surfaces may seriously affect handling and control of the vehicle, and may cause the vehicle to go out of control.

Avoid operating the vehicle on pavement. If you must operate on a paved surface, travel slowly and do not make sudden turns or stops.

WARNING

POTENTIAL HAZARD Operating this vehicle without proper instruction WHAT CAN HAPPEN Loss of control, accident HOW TO AVOID THE HAZARD The risk of an accident is greatly increased if the operator does

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

All operators must read and understand the Owner’s Manual and all warning and instruction labels on the vehicle.

WARNING

Page 18

SAFETY

Operator Safety

POTENTIAL HAZARD Operating this vehicle on public streets, roads or highways WHAT CAN HAPPEN Collision with another vehicle HOW TO AVOID THE HAZARD Never operate this vehicle on any public street, road or

highway, including dirt or gravel. In many states it’s illegal to operate vehicles of this type on

public streets, roads and highways.

WARNING

POTENTIAL HAZARD Operating this vehicle 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 vehicle.

WARNING

Page 19

SAFETY

Operator Safety

POTENTIAL HAZARD Operating this vehicle at excessive speeds WHAT CAN HAPPEN Loss of control, accident HOW TO AVOID THE HAZARD Always travel at a speed proper for the terrain, visibility and

operating conditions, and your experience.

WARNING

POTENTIAL HAZARD Attempting jumps and other stunts WHAT CAN HAPPEN Loss of control, accident and/or vehicle overturn HOW TO AVOID THE HAZARD Never attempt jumps and other stunts. Avoid exhibition driving.

WARNING

Safe operation of this 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.

WARNING

Page 20

SAFETY

Operator Safety

POTENTIAL HAZARD Failure to inspect the vehicle before operating Failure to properly maintain the vehicle WHAT CAN HAPPEN Accident, equipment damage HOW TO AVOID THE HAZARD Always inspect your UTV before each use to make sure it’s in safe

operating condition. Always follow the inspection and maintenance procedures and

schedules described in the Owner’s Manual.

POTENTIAL

HAZARD

Failure to use extra caution when operating this vehicle on unfamiliar terrain

WHAT CAN

HAPPEN Loss of control, vehicle overturn HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar

terrain. Always be alert to changing terrain conditions when operating the

vehicle. Yo u may come upon hidden rocks, bumps, or holes suddenly , without enough time to react.

WARNING

Page 21

SAFETY

Operator Safety

POTENTIAL HAZARD Operating this vehicle with improper tires or with improper or

uneven tire pressure WHAT CAN

HAPPEN Loss of control, accident and/or overturn HOW TO AVOID THE HAZARD Always use the size and type of tires specified in the Owner’s

Manual for this vehicle. See page 97. Always maintain proper tire pressure as described on the decal

and in the Owner’s Manual. See page 97.

WARNING

POTENTIAL HAZARD Failure to follow the minimum age recommendations for this

vehicle WHAT CAN

HAPPEN Serious injury or death (the child or others) HOW TO AVOID THE HAZARD Only persons with a valid driver’s license should operate a Polaris

UTV. Even though a child may be within the age group for which some

vehicles are recommended, he or she may not have the skills, abilities, or judgment needed to operate the vehicle safely and may be involved in a serious accident.

WARNING

Page 22

SAFETY

Operator Safety

In the event of an accident, have a qualified service dealer inspect the complete machine for possible damage, including (but not limited to) brakes, throttle, and steering.

WARNING

POTENTIAL HAZARD Operating this vehicle with improper modifications WHAT CAN HAPPEN Loss of control, accident HOW TO AVOID THE HAZARD Improper installation of accessories or modification of this vehicle

may cause changes in handling that in some situations could lead to an accident.

Never modify this vehicle through improper installation or use of accessories. All parts and accessories should be genuine Polaris Sales Inc. or equivalent components designed for use on the vehicle, and they should be installed and used according to instructions. See your authorized Polaris dealer.

WARNING

Page 23

SAFETY

Operator Safety

Driving On Slippery Surfaces

Extra caution is required when operating on slippery surfaces. Loss of tire traction and vehicle control can result in an accident, including an overturn.

Never apply brakes during a skid. Complete loss of control can result.

Avoid operating on excessively slippery surfaces. Always reduce speed and use additional caution.

WARNING

When driving on slippery surfaces such as wet trails, loose gravel, or ice, be alert for the possibility of skidding and sliding. Under these conditions, follow these precautions:

1. Slow down when entering slippery areas.

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

3. Correct a skid by turning the steering wheel in the direction of the skid.

4. Drive with AWD engaged to assist in controlling the vehicle.

CAUTION

Engaging AWD while the wheels are spinning can cause severe damage to the drive train.

Before operating your vehicle on a frozen body of water, be sure the ice is thick enough to support the machine and its operator, as well as the force created by a moving vehicle. Severe injury or death can result if the vehicle and/or its operator break through the ice.

WARNING

Page 24

SAFETY

Operator Safety

Operating on Hills

Climbing hills improperly can cause loss of control or vehicle overturn. Always check the terrain carefully before climbing a hill.

Never climb hills with excessively slippery or loose surfaces. Never open the throttle suddenly. Never go over the crest of a hill at high speed. An obstacle, a

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

WARNING

When traveling uphill:

1. Drive straight uphill.

2. Avoid steep hills.

3. Keep both feet on the floor.

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

Traveling downhill improperly could cause loss of control or vehicle overturn. Always check the terrain carefully before descending a hill.

Never descend a hill at high speed. Excessive speed may result in loss of vehicle control and lead to serious injury or death.

Avoid descending a hill at an angle, which would cause the vehicle to lean sharply to one side. Travel straight downhill when possible.

WARNING

When descending a hill:

1. Drive directly downhill.

2. Slow down.

3. Apply the brakes lightly to aid in slowing.

Page 25

SAFETY

Operator Safety

Operating on Hills

Braking and handling are greatly affected when operating in hilly terrain. Loss of vehicle control or overturning of the vehicle could occur.

Avoid climbing steep hills (15_ maximum). Use extreme care when operating your vehicle in hilly terrain.

WARNING

15_ Maximum

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

If at all possible, avoid crossing the side of a steep hill. Avoid hills with excessively slippery or loose surfaces.

WARNING

Page 26

SAFETY

Operator Safety

Crossing Streams

Never try to cross a deep or fast-flowing stream. The large tires can cause the vehicle to float, resulting in loss of control.

WARNING

Your Polaris UTV can operate through water up to depths reaching the floorboards. Before fording streams:

1. Always determine water depths and current.

2. Always choose a crossing where both banks have gradual inclines.

3. Always proceed slowly, avoiding rocks and obstacles.

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

NOTE: After running the vehicle in water, it is critical that your machine is serviced as outlined in the Periodic Maintenance Schedule beginning on page 56. Give special attention to engine oil, transmission oil, front and rear gearcases, and all grease fittings.

CAUTION

Should your vehicle become immersed, take it to your dealer as soon as possible for service. Do not start the engine! Immersion can result in major damage if not correctly serviced.

If this is impossible, service your machine as outlined on page 72, and take the machine to your dealer at your first opportunity.

Page 27

SAFETY

Operator Safety

Trail Obstacles

Stay alert! Look ahead and learn to read the trail as you drive. Stay on the righthand side of the trail and be constantly alert for hazards such as logs, rocks and low hanging branches.

Hidden or unseen hazards on the trail can be dangerous. Personal injury or the vehicle overturning can occur from unseen

obstacles. Stay alert and constantly look for obstacles on the trail.

WARNING

Page 28

SAFETY

Operator Safety

Operating in Reverse

1. When 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. Always inspect left and right fields of vision before backing.

Backing your UTV can be dangerous! You could collide with an obstacle or person behind you, or the vehicle could overturn on a steep incline.

Always back slowly, avoiding excessive speed. Avoid backing on steep inclines.

WARNING

Page 29

SAFETY

Operator Safety

ParkingOnAnIncline

1. Place the transmission in gear.

2. Set the parking brake.

3. Avoid parking on an incline. If it is necessary to park on an incline, always block the rear wheels on the downhill side.

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

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

WARNING

Page 30

SAFETY

Operator Safety

Carrying Loads

The UTV has been designed to carry or tow specific capacities. Always read and understand the load distribution warnings listed on the warning labels. Never exceed the following capacities.

Maximum Capacities

(Level Ground)

Cargo Box

UTV 2X4 1350 lbs. (614 kg) 850 lbs. (386 kg) UTV 4X4 1500 lbs. (681 kg) 1000 lbs. (454 kg)

Load Distribution

1. Always load the cargo box with the load as far forward as possible.

2. Always operate the vehicle with extreme care when hauling or towing loads.

3. Slow down and drive in low gear.

Never operate this vehicle with the cargo box in the raised position. The cargo box could close unexpectedly while driving, severely injuring the driver. The rear tires will catch the rear of the box, damaging the vehicle and creating hazardous driving conditions.

Do not overload the vehicle.

WARNING

Page 31

SAFETY

Operator Safety

Dumping the Ca rgo Box

1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline.

2. Set the parking brake.

3. Press and hold the cargo box dump switch in the upward position to dump.

4. Press and hold the cargo box dump switch in the downward position to return the box to a l evel position.

Never carry passengers in the cargo box. Passengers should always ride in the cab with seat belts

fastened securely.

WARNING

Page 32

SAFETY

Operator Safety

Towing Loads

Maximum Towing Capacities (Level Ground)

Total Towed

Load Weight

(level ground)

Total Towed

Load Weight

(15° grade)

Total Hitch

Vertical

Weight

Towing

Speed

UTV 2X4 1400 lbs.

(636 kg)

800 lbs.

(364 kg)

150 lbs

(68.1 kg)

10 mph

(16 kph)

or less

UTV 4X4 1500 lbs.

(681 kg)

850 lbs.

(386 kg)

150 lbs

(68.1 kg)

10 mph

(16 kph)

or less

Do not tow in high gear. Drive belt life will be affected. Maximum grade while trailer towing is 15°. Do not tow any trailer on

a grade steeper than 15°.

Never carry a passenger in a trailer. Never load more than 150 lbs. (68.1 kg) tongue weight on the

towing bracket. Do not operate the vehicle faster than 10 mph (16 km/h) when

towing. Towing a trailer increases braking distance. Do not tow more than the recommended weight. See page 96. Attach a trailer to the trailer hitch bracket only. Do not attach a

trailer to any other location or you may lose control of the vehicle.

WARNING

Page 33

SAFETY

Operator Safety

Parking the UTV

1. Stop the vehicle on a level surface.

2. When the engine has stopped, apply the parking brake to help prevent the vehicle from rolling.

Always apply the parking brake before leaving the vehicle. If the vehicle should roll, it may cause damage or injury.

WARNING

3. Remove the ignition switch key to prevent unauthorized use.

NOTE: When parking inside a garage or other structure, be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks, including any appliance with pilot lights.

Gasoline is extremely flammable and can be explosive under certain conditions.

WARNING

Page 34

SAFETY

Safety Decals and Locations

S VEHICLE ROLLOVER could cause severe injury or death This cab frame is not designed or intended to provide rollover protection.

S ALWAYS WEAR YOUR SEAT BELT for maximum protection.

WARNING

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

TIRE PRESSURE (PSI): FRONT 10 REAR 10

MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight)

INCLUDING MACHINE, DRIVER AND CARGO IS 2750 LBS.

Reduce speed and allow greater distance for braking when carrying cargo. Overloading or carrying tall, off-center, or unsecured loads will increase your risk of losing control. Loads should be centered and carried as low as possible in box. For stability on rough or hilly terrain, reduce speed and cargo. Be careful if load extends over the side of the box.

Read Owner’s Manual for more detailed loading information.

7079424

7079425

Location 1

S Moving parts hazard under belt-clutch guard. To

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

S Do not modify engine or clutch. Doing so can

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

WARNING

7078689

NO STEP

Location 2

Location 3

Page 35

SAFETY

Safety Decals and Locations

ATTENTION

D Operation of this vehicle without

the filter element will severely damage the engine.

D Clean air filter often, more

frequent cleaning required in dusty conditions

D Operation of this vehicle without

engine breather filter(s) can cause engine damage. Consult owner’s manual for details.

D Specific

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

Factory setting:

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

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

7079902

Location 4

Page 36

SAFETY

Safety Decals and Locations

MANUFACTURED BY: POLARIS IND INC.

DATE:

VIN:

THIS VEHICLE IS A GENERAL PURPOSE OFF-ROAD UTILITY VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS.

PRINTED IN U.S.A.

7078472

CE VÉHICULE USAGE GENERAL VEHICULE UTILITAIRE POUR SERVICE HORS ROUTE QUI NEST PAS DESTINE A ETRE UTILISE SUR LES CHEMINS PUBLICS.

Remove flammable containers from box before refueling.

Location 5 (under hood)

Location 6 (inside, front of box)

Fuel / Passenger Warning Decal Text

Remove flammable containers from box before refueling. S Passengers can be thrown off. This can cause serious injury or

death.

S Never carry passengers in cargo box. Maximum2x4BoxLoad850lbs.

Maximum4x4BoxLoad1000 lbs.

Page 37

SAFETY

Safety Decals and Locations

WARNING

Location 7

Warning Decal Text

Improper vehicle use can result in SEVERE INJURY or DEATH.

NEVER:

S Operate on public roads. A collision can occur with another vehicle. S Carry more than two passengers, or passengers under age five. S Use ALCOHOL or DRUGS before or while operating this vehicle. S Operate at speeds too fast for your skills or the conditions. S Operate this vehicle on HILLS steeper than 15 degrees. To prevent

flipover on hilly terrain, use throttle and brakes gradually.

ALWAYS:

S Avoid paved surfaces which may adversely affect handling and con-

trol.

S Use proper RIDING TECHNIQUES to avoid vehicle overturns on

hills and rough terrain and in turns.

S Wear eye protection. REVERSE operation can be dangerous, even at low speeds. Steering

becomes difficult. To prevent flipover, avoid sharp turns. The park/emergency brake lever will supply increased braking, but

should be used as an emergency or parking brake only.

READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS

AND WARNINGS. IF OWNER’S MANUAL IS MISSING,

CONTACT A POLARIS DEALER FOR A REPLACEMENT.

THIS GENERAL PURPOSE OFF-ROAD UTILITY VEHICLE DOES

NOT MEET FEDERAL MOTOR VEHICLE SAFETY STANDARDS

FOR ON ROAD VEHICLES.

Page 38

FEATURES AND CONTROLS

Features

1. Cab Frame

2. Cab Frame Hand Hold

3. Dashboard

4. Steering Wheel

5. Seat

6. Cargo Box

7. Seat Belts

8. Fuel Tank Cap / Fuel Gauge

9. Battery (under seat)

Page 39

FEATURES AND CONTROLS

Features

10. Headlights

11. Radiator

12. Front Bumper/Brush Guard

13. Hood Hold Down Strap

Page 40

FEATURES AND CONTROLS

Features

14. Oil Tank

15. Battery (Under Seat)

16. Tail Lights

17. Tail Gate

18. Tailgate Latch Release

19. Airbox (under cargo box)

20. Muffler (Spark Arrester)

21. Rear Caliper

22. Trailer Hitch Receiver

23. Engine Oil Plug

Page 41

FEATURES AND CONTROLS

Features

Auxiliary Lighting/Electrical Accessory Terminals

The 12-volt receptacle (1) has spade connections on the back that may be used to power an auxiliary light or other optional lights or accessories.

To locate these connections, lift the hood and look behind the dash board.

Trailer Hitch Bracket

This vehicle is equipped with a receiver hitch bracket for a trailer hitch. Trailer towing equipment is not supplied with this vehicle.

To avoid injury and property damage, observe the precautions on page 30.

Seat Belts

The vehicle is equipped with lap-style seat belts for the operator and passenger.

Seat belts reduce injury. Always wear your seat belt. Minimum age recommendation for passengers is five years old.

Passengers under five years of age require special restraints, which are not available with this vehicle.

WARNING

To wear the seat belt properly, follow this procedure:

1. Place the belt across your lap as low on your hips as possible, taking care that t he belt is not twisted.

2. Push the latch plate into the buckle until it clicks.

3. Release the strap, it will self tighten. NOTE: The center belt must be tightened manually by pulling on the strap.

To unfasten, press the square red button in the buckle’s center.

Page 42

FEATURES AND CONTROLS

Features

Seat Removal

Pull up on the front of the seat and slide it toward the front of the vehicle.

Install the seat by sliding the tabs into the rear of the seat base. Push down firmly on the front of the seat until the pins are fully seated into the grommets.

Fuel Cap/Fuel Gauge

The fuel tank filler cap (1) is located on the righthand side of the vehicle near the passenger seat. It has a built-in fuel gauge that indicates the amount of fuel remaining in the tank.

When the indicator needle nears the E (empty) mark, refuel at the earliest opportunity.

When refueling, always use either leaded or unleaded gasoline with a minimum pump octane number of 87 R+ M/2 octane.

Page 43

FEATURES AND CONTROLS

Controls

1. Choke Knob

2. Ignition Switch

3. Hour Meter

4. Indicator Lights

5. 12V Accessory Plug

6. Fog/High Beam Light S witch

7. AWD (All Wheel Drive) Switch (if equipped)

8. Shift Lever

9. Differential Lock Lever

10. Cargo B ox Dump Switch

Page 44

FEATURES AND CONTROLS

Controls

Transmission Gear Selector Operation

The transmission gear selector (1) is located on the console to the right of the steering wheel. It has four positions (2): high, low, neutral and reverse.

NOTE: Low is the primary driving range for this vehicle. High is intended for use on hard packed surfaces with light loads.

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 transmission in gear with the parking brake locked whenever the vehicle is left unattended.

Maintaining shift linkage adjustment is important to assure proper transmission function. See your dealer if you experience any shifting problems.

NOTE: This vehicle is equipped with a reverse alarm. The alarm is activated when the transmission is shifted to reverse.

Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission could result.

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

CAUTION

Page 45

FEATURES AND CONTROLS

Controls

Brake Pedal

The brake pedal (1) is the left pedal on the foot board. Depress the brake pedal to slow or stop the vehicle.

Throttle Pedal

The throttle pedal (2) is the right pedal on the floor board. Push the pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check that the throttle pedal returns normally before starting the engine. In addition, there must be adequate throttle pedal play. Refer to page 79 for throttle pedal adjustment procedure.

Indicator Lights

There are indicator lights on the dash panel for the following:

1. High

2. Low

3. Neutral

4. Reverse

5. High Temperature

6. Brakes

BRAKE

Page 46

FEATURES AND CONTROLS

Controls

Ignition Switch (1)

The ignition switch is a three-position, key-operated switch. The key can be removed from the switch when it is in the OFF position.

Light Switch (2)

Turn the headlights and taillights on by flipping the light switch up (the ignition switch key must be in the ON position). Flip the switch down to turn the lights off.

AWD Switch (3)

Vehicles equipped with AWD can be operated in either 2WD or AWD. Flip the AWD switch up to engage the AWD. Flip the switch down to return to 2WD.

Under some conditions, it’s possible for the AWD to remain engaged. See page 99 for manual disengagement instructions.

Cargo Box Dump Switch (4)

The cargo box can be dumped or lowered by holding the dump switch down (to dump) or up (to lower).

OFF ON

START

Engine off. All electrical circuits are off except Acc. 12V. Electrical circuits are on. Electrical equipment can be used.

Electric starter is engaged by holding ignition switch key in this position. Upon release, the key will return to the ON position.

CAUTION

Do not operate the starter continuously for more than five seconds or the starter will overheat and the battery power will drop temporarily. Wait at least five seconds between each operation of the starter to allow it to cool and to allow battery power recovery.

Do not turn the ignition switch key to the START position while the engine is running. Damage to the starter can result.

Page 47

FEATURES AND CONTROLS

Controls

All Wheel Drive (AWD)

Your Polaris UTV 4X4 is equipped with an exclusive Polaris All Wheel Drive (AWD) system that can be activated by a switch on the dash. When the switch is off, the UTV is in two-wheel drive at all times. When the switch is on, the UTV is in AWD, and the front wheels will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the front wheels will automatically disengage.

The AWD switch position indicates when the vehicle is in AWD. There is no limit to the length of time the vehicle may remain in AWD.

The AWD 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

If the rear wheels are spinning, release the throttle before turning the AWD switch on. If AWD is engaged while the wheels are spinning, severe drive shaft and clutch damage could result.

Page 48

FEATURES AND CONTROLS

Controls

Parking Brake Lever

The parking brake (1) is located below t he dash in the center of the vehicle. It will help prevent the vehicle from rolling while parked.

To apply the parking brake, push down on the pedal with your foot.

To release, pull the release handle (2), which is located below the dash. Spring pressure helps return the lever to the released position.

Make sure the parking brake lever is functioning properly before each operation.

Differential Lock

The rear axle is equipped with a lockable differential that allows the operator to choose between an open differential or a closed differential. It’s beneficial to lock the differential in low traction situations.

The differential lever is located on the console (3). Pull the lever down to lock.

CAUTION

Damage to the differential can occur if it is engaged when the vehicle is traveling at high speeds or while the rear wheels are spinning.

Page 49

OPERATION

Before You Ride

Daily Pre-operation Inspection

If a proper inspection is not performed, serious injury or death can result. Always inspect your UTV before operating.

WARNING

Inspect your vehicle before each operation to ensure it’s in proper working order.

Before operating your vehicle, inspect all operating controls and parts.

Item/Inspection Procedure

1. Tires - check condition and pressures

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

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

4. Throttle - check for free operation and closing

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

6. Engine ignition 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. Air cleaner element - check for dirt; clean or replace

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

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

11. Operator and passenger should be properly dressed.

12. Engine coolant - check for proper level in the overflow bottle.

13. Check condition and operation of the dump box/bed latch mechanism.

Page 50

OPERATION

Vehicle Break-In Period

The break-in period for your new Polaris UTV is the first twenty hours of operation, or the time it takes to use the first two tanks full of gasoline. No single action on your part is as important as a proper break-in period. Careful treatment of a new engine will result in more efficient performance and longer life for the engine. Perform the following procedures carefully.

1. Fill the fuel tank with either unleaded or leaded fuel that 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 open area t hat will give you room to familiarize yourself with vehicle operation and handling.

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

5. Perform regular checks on fluid levels, controls and other important areas on the vehicle as outlined on the daily pre-operation inspection checklist found on page 47.

6. Pull only light loads.

7. Break in oil and filter. Change both at 25 hours.

CAUTION

Mixing oil brands or using non-recommended oil may cause engine damage. If using non-recommended engine oil is determined to have caused engine damage, repair and/or replacement will not be covered under Polaris warranty.

We recommend the use of Polaris Premium 4 All Season Synthetic Oil or API certified “SH” oil. Never mix oil brands.

ADD 8 OZ. NORMAL FULL

Maintain Oil Level In Normal Range

CAUTION

Operating at full throttle or high speeds for extended periods during the first three hours of use may cause excessive heat, resulting in damage to close-fitted engine parts.

Page 51

OPERATION

Starting the Engine

Do not start or operate this vehicle with sticking or improperly operating throttle pedal. Doing so could cause an accident leading to severe injury or death.

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

Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle pedal sticks during operation.

Always check the pedal for free movement and return before starting the engine and occasionally during operation.

WARNING

Procedure for Starting a Cold Engine

1. Place the transmission in neutral.

2. Lock the parking brake.

3. Sit in the driver’s seat and fasten your seat belt.

4. Pull the choke knob all the way out.

5. Turn the ignition key to START.

6. If the engine does not start within five seconds, release the ignition switch and wait five seconds. Turn the ignition switch to START for another five seconds. Repeat this procedure until engine starts.

NOTE: Do not press the throttle pedal while starting t he engine.

7. If the engine slows or stops, push the choke knob in half way.

8. Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly. Then push the choke all the way in.

Page 52

OPERATION

Starting the Engine

CAUTION

Improper engine warm-up may cause engine damage. Follow recommended engine starting procedures.

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

WARNING

The engine exhaust from this

product contains chemicals

known to cause cancer, birth de-

fects or other reproductive harm.

WARNING

Page 53

OPERATION

Starting the Engine

Procedure for Starting a Warm Engine

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

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

2. Lock the parking brake.

3. Sit in the driver’s seat with the seat belt fastened.

4. Turn the ignition key to START.

5. If the engine has cooled and does not readily start, intermittent use of the choke knob (pulled half way out) may be necessary.

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

7. Release the throttle lever immediately after the engine starts.

NOTE: If the engine does not start and all conditions are favorable, change the spark plug.

Page 54

OPERATION

Driving the UTV

1. Sit in the driver’s seat with the seat belt fastened.

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. Keeping both hands on the steering wheel, slowly depress the throttle with your right foot and begin driving. Vehicle speed is controlled by the amount of throttle opening and Polaris Variable Transmission (PVT) shifting is automatic.

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

Braking

1. Release the throttle pedal completely

2. Press on the brake pedal evenly and firmly.

NOTE: Practice starting and stopping (using the brakes) until you are familiar with the controls.

NOTE: When the throttle pedal is released completely and the engine speed drops near an idle, the vehicle has no engine braking.

CAUTION

Low is the primary gear for operating this vehicle. High gear is intended for use on hard-packed surfaces with light loads.

Premature belt wear may result from operating in a gear that’s unsuitable for the terrain.

When carrying cargo or towing a trailer, load weight will increase braking distances. Failure to allow for increased braking distance may result in accident and injury.

WARNING

Page 55

OPERATION

Stopping the Engine

1. Release the throttle pedal completely and brake t o a complete stop.

2. Put the gear shift lever into neutral.

3. Apply the parking brake to help prevent the vehicle from rolling.

Always apply the parking brake before leaving the vehicle. Movement may result in damage or personal injury.

WARNING

Page 56

OPERATION

Refueling

Gasoline and Alcohol Blends

Blends of gasoline and alcohol called “gasohol” may be used on an occasional basis, but continued use is not recommended. Immediately switch back to gasoline, which does not contain alcohol, if you experience any operating irregularities. Any deterioration of fuel system components or degradation of performance resulting from the use of gasohol is not covered by Polaris Warranty.

n Never use gasohol with an octane rating lower than the minimum

octane rating specified for this product. Always use either leaded or unleaded gasoline with a minimum pump octane number of 87 R+ M/2 octane.

n Never use gasohol containing more than 10% ethanol (grain

alcohol).

n Never use gasohol containing more than 5% methanol (wood

alcohol). Gasoline containing methanol must also be blended with cosolvents and corrosion inhibitors.

n Never use gasohol for extended periods and never store this vehicle

with gasohol in the fuel system.

n Gasoline containing alcohol can cause paint damage. Do not spill

gasohol during refueling.

Gasoline is highly flammable and is explosive under certain conditions. Always exercise extreme caution whenever handling gasoline.

Always stop the engine when refueling. Always refuel outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the

refueling area or where gasoline is stored. Do not over fill the tank. Do not fill the tank neck. If gasoline spills on your skin or clothing, immediately wash it off

with soap and water and change clothing. Never 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.

WARNING

Page 57

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 inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery t o the ultimate purchaser or while it is in use or

2. The use of the vehicle after such device or element of 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. Replacement of any vehicle parts with parts not in compliance with federal regulations.

4. Lack of proper maintenance.

Do not touch hot exhaust system components. Serious burns can result.

Use extra caution when traveling through tall grass. The potential for fire exists.

USFS Approved Spark Arrestor

The muf fler on this vehicle was tested and approved in accordance with the USFS Forest S ervice Standard 5100-1A.

CAUTION

Exhaust system components are very hot during and after use of the vehicle and will cause burns if they come in contact with skin.

Page 58

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

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

Maintenance intervals are based upon average operating conditions. 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: When inspection reveals the need for replacement parts, use

genuine Polaris parts available from your Polaris dealer.

Item Frequency Remarks

Brake System Pre-operation Inspect Tires Pre-operation Inspect Wheels Pre-operation Inspect Frame nuts, bolts,

fasteners

Pre-operation Inspect

Parking Brake Pre-operation Check lever adjustment daily; ad-

just Throttle Cable Pre-operation Inspect Steering Pre-operation Inspect Coolant/Level Daily Replace coolant every two years Headlamp Daily Inspect operation daily; apply Po-

laris dielectric grease to connector

when replaced

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

CAUTION

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

Page 59

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item Frequency Remarks

Tail lamp Daily Check daily; apply Polaris dielectric

grease to socket when replaced

"LAirFilter-MainEle-

ment

Weekly Inspect; replace if necessary

" Transmission Oil 25 hrs Check level; change oil annually

Battery 25 hrs Check terminals; clean; check fluid

level

J Brake pad wear 25 hrs Inspect periodically

"LEngine breather filter 25 hrs Inspect, replace annually and as

needed

" General Lubrication 25 hrs Lubricate all fittings, pivots, cables,

etc.

Engine Cylinder Head/Cylinder Base Fasteners

25 hrs Re-torque required at first service

only

" Engine Oil - Level 25 hrs Check level daily; break-in service

at 25 hours.

"LEngine Oil - Change

(4-Cycle)

100 hrs Change oil at 100 hours, more often

in cold weather use.

"LOil Filter 100 hrs Replace with oil change

L Engine breather

hose

100 hrs Inspect

J Carburetor Float

Bowl

50 hrs Drain bowl periodically and prior to

storage

J Throttle Cable 50 hrs Inspect; adjust, lubricate, replace if

necessary

L Choke (Enricher)

Cable

50 hrs Inspect; adjust, lubricate, replace if

necessary

Shift linkage 50 hrs Inspect; adjust

J Drive belt 50 hrs Inspect; adjust, replace if necessary

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

Page 60

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item Frequency Remarks

J Steering 50 hrs Inspect; lubricate " Front Suspension 50 hrs Inspect; lubricate, tighten fasteners " Rear Suspension 50 hrs Inspect, tighten fasteners

Coolant strength/ pressure test system

100 hrs Inspect strength seasonally; pres-

sure test system annually

Engine Mounts 100 hrs Inspect

JLValve Clearance 100 hrs Inspect; adjust

L Spark Plug 100 hrs Inspect; replace if necessary

JLIgnition Timing 100 hrs Inspect and adjust as needed

J Front Hub Bearings 100 hrs Check at 100 hours and replace as

required

JLFuel System 100 hrs Check for leaks at fuel cap, lines,

fuel valve, filter, pump and carburetor. Replace lines every two years.

J Fuel Filter 100 hrs Replace annually

Cooling System hoses

100 hrs Inspect

Spark arrestor 100 hrs Clean out

" Front Gearcase Oil 100 hrs Check monthly; change annually J Clutches (drive and

driven)

100 hrs Inspect, clean

J Brake fluid 200 hrs Change every two years J Front wheel bearings 300 hrs Inspect; replace if necessary L Idle Speed As Required Adjust

Engine side cover As required Drain moisture after driving in water

J Toe adjustment As required Periodic inspection, adjust when

parts are replaced

Headlight Aim As required Adjust if necessary

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

Page 61

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Item Lube Method Frequency*

Engine Oil Polaris Pre-

mium 4 Synthetic 0W40

Add to proper level on dipstick. See page 64.

Check level daily.

Brake Fluid DOT 3 Only Maintain level between fill

lines. See page 81.

As required; change every 200 hours

Transmission Oil

Polaris Premium Synthetic chain case lube

Maintain level at the bottom of the fill plug threads. See page 65.

Change at 100 hours

1. Front Gearcase Oil

Premium Hub Lube

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

Change annually

2. Prop Shaft U-joints

Grease+ Locate Fittings and Grease 50 hours

Front Propshaft Yoke

Grease+ Locate fittings and grease (3

pumps maximum)

50 hours

Front Drive Axle (U Joint)

Grease+ Locate grease fitting and

grease with grease gun.

50 hours

Ball Joint Grease** Locate fitting on back side of

struts and grease with grease gun.

50 hours

3. Swing Arm Bushings

Grease** Locate fittings on swing arm

and grease with grease gun.

25 hours

Rear angle drives

GL5 80-90 weight gear lube

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

50 hours

4. Front A Arm Pivot Shaft

Grease**∆ Locate fitting on pivot shaft

and grease with grease gun.

50 hours

* 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 50 hours, or after submerging in water or before long periods of storage or after pressure washing. We recommend use of 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.

Page 62

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Page 63

MAINTENANCE AND LUBRICATION

Oil System

Checking the Oil

The oil tank is located under the seat. To check the oil:

1. Position the machine on a level surface.

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

3. Stop the engine and remove the seat as described on page 40.

4. Remove the dipstick (1) and wipe it dry with a clean cloth.

5. Replace the dipstick and screw it in completely. NOTE: The dipstick must be screwed in to keep the angle and depth of stick consistent.

6. Remove the dipstick and check to see that the oil level is between the full and add marks (2). Add oil if necessary. Do not overfill.

ADD 8 OZ. NORMAL FULL

CAUTION

We recommend the use of Polaris Premium 4 All Season Synthetic Oil or API certified “SH” oil. Never mix oil brands.

Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury.

WARNING

Page 64

MAINTENANCE AND LUBRICATION

Oil System

Oil and Filter Change

Maintain the engine oil at the proper level to ensure a properly functioning engine, and change the oil and oil filter in accordance with the Periodic Maintenance Schedule. Dirt and metal particles collect in the oil, and oil loses its lubricative quality if used too long.

The recommended oil change interval is 100 hours or every six months, whichever comes first. Suggested break-in oil change is at 25 hours, 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 weather operation. NOTE: Severe use/cold weather operation is when all operating is at below 10° F. and/or when operating between 10° F and 30°F if most trips are slow speed and less than five miles. Always change the oil filter when changing oil.

PROCEDURE:

1. Position the vehicle on a level surface.

2. Clean the area around the drain plug at the bottom of the oil tank.

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

4. Place a drain pan beneath the oil tank and remove the drain plug.

5. Allow oil to drain completely.

6. Install a new sealing washer (PN 5850135) 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).

CAUTION

Oil may be hot. Do not allow hot oil to come into contact with skin. Serious burns may result.

Page 65

MAINTENANCE AND LUBRICATION

Oil System

Oil and Filter Change (con t .)

8. Disconnect the lower oil delivery hose. Remove the fitting (1) from the oil tank. Clean the fitting screen. Reinstall the fitting screen, torquing to 14-17 ft. lbs. Reattach the oil line. Torque the banjo fitting (2) to 14-17 ft. lbs.

9. Place shop towels beneath the oil filter. Using an oil filter wrench, t urn t he filter (3) counterclockwise to remove.

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

11. Lubricate the o-ring on the 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 the new filter (3) and tighten by hand 1/2 to 3/4 turn after gasket contact.

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

Page 66

MAINTENANCE AND LUBRICATION

Oil System

Oil and Filter Change (con t .)

14. Reinstall drain plug.

15. Remove dipstick and add two quarts (1.9 l.) of Polaris Premium 4 synthetic oil. Reinstall dipstick. NOTE: If sump is not drained, add about 1 3/4 quarts initially.

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

17. Start engine and let it idle for 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.

4 Cycle Premium 4 Synthetic Lubricant

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

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

Although Polaris Premium 4 is the only oil recommended for use in this engine, use of any API certified “SH” oil is allowable. Oil may need to be changed m ore frequently if Polaris Premium 4 is not used. Follow the manufacturer’s recommendations for ambient temperature operation.

Fuel Filter

Your Polaris UTV is equipped with an in-line fuel filter that should be replaced by your dealer after every 100 hours of operation.

Do not attempt to clean these filters.

Page 67

MAINTENANCE AND LUBRICATION

Transmission Oil

The transmission lubricant level should be checked at 25 hours or monthly, whichever comes first. Transmission oil should be changed annually.

1. Position the vehicle on a level surface.

2. Remove the fill plug (1), which is located on the righthand side of the machine.

3. Check the lubricant level. Lubricant should be kept at the bottom of the fill plug threads.

NOTE: We recommend the use of Polaris Premium Synthetic Gearcase Lubricant for optimum performance.

CAUTION

Do not allow dirt or foreign materials to enter the transmission case.

Page 68

MAINTENANCE AND LUBRICATION

Front Gearcase

Gearcase Lubrication

The front gearcase lubricant level should be checked every six months or 100 hours, whichever comes first. Front gearcase oil should be changed annually as outlined in the Periodic Maintenance Schedule.

If the machine is used in wet conditions, the oil should be checked more frequently.

If the oil has a milky appearance, it should be changed as soon as possible.

Failure to properly maintain this important area can result in premature wear or possible failure of the front grease components.

NOTE: We recommend the use of Polaris Premium Hub Oil for optimum performance.

The front gearcase fill plug (1) is located on the right side of the front gearcase.

1. With the UTV on a level surface, remove fill plug and check the lubricant level. Lubricant should be kept at the bottom thread of the fill plug hole.

2. Support vehicle securely with a jack stand.

3. Remove the front tire on the driver’s side.

4. Remove fill plug.

5. Remove gearcase drain plug (2) located on the bottom right hand side and drain the oil. Catch and discard used oil properly.

6. Clean and reinstall the drain plug.

7. Add hub oil to the bottom thread of the fill plug hole.

8. Check for leaks.

Page 69

MAINTENANCE AND LUBRICATION

Cooling System

Operation

The overflow bottle (1) is located in front of the right front tire of the machine. The coolant level must be maintained between the minimum and maximum marks on the overflow bottle.

The engine coolant level is controlled or m aintained by the recovery system. The recovery system components are the overflow 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 overflow bottle. As engine coolant temperature decreases, the contracting (cooled) coolant is drawn back up from the tank, past the pressure cap, and into the radiator.

NOTE: Some coolant level drop on new machines is normal as the system is purging itself of trapped air. Observe coolant levels and maintain as recommended by adding coolant to the overflow bottle.

Page 70

MAINTENANCE AND LUBRICATION

Cooling System

Coolant Level Inspection

NOTE: Check the coolant level when the engine is cold (room or atmospheric temperature).

1. Situate the vehicle on level ground.

2. Check the coolant level by looking at the overflow bottle located in front of the right front wheel. The coolant level should be between the minimum mark (1) and the maximum mark (2).

3. If the amount of coolant is not within the operating range, lift the hood and locate the overflow bottle lid. Remove the lid and use a funnel to add coolant through the filler opening until the fluid level has reached the maximum mark. Reinstall the cap.

NOTE: 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’s mixing recommendations for the freeze protection required in your area.

NOTE: In an emergency you can add water alone to the overflow bottle, but it must be returned to the correct mixture ratio by adding antifreeze concentrate as soon as possible.

CAUTION

If coolant must be added often, or if the overflow bottle runs completely dry, there may be a leak in the system. Have the cooling system inspected by your Polaris UTV dealer.

Page 71

MAINTENANCE AND LUBRICATION

Cooling System

Radiator Coolant Level Inspection

1. Lift the hood and locate the radiator cap(1).

2. Visually inspect the level of coolant in the radiator.

3. Using a funnel, slowly add coolant if necessary.

NOTE: This procedure is only required if t he cooling system has been drained for maintenance and/or repair. However, if the overflow bottle has run dry, the level in the radiator should be inspected and coolant added if necessary.

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.

Changing Coolant

To ensure that the coolant m aintains its ability to protect the engine, the system be completely drained every two years, and a fresh mixture of antifreeze and water should be added. Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water.

NOTE: Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water.

NOTE: Always follow the manufacturer’s mixing recommendations for the freeze protection required in your area.

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.

WARNING

Page 72

MAINTENANCE AND LUBRICATION

Cooling System

Radiator and Cooling Fan

Check and clean the screen and radiator fins for obstructions caused by insects or mud as outlined in the Periodic Maintenance Schedule.

Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan. Interference with the radiator air flow can lead to overheating and consequent engine damage.

Coolant absorbs excessive heat from the engine and transfers it to the air at the radiator. If the coolant level becomes low, the engine overheats and may suffer damage. Check the coolant level each day before operating the vehicle, and replenish coolant if the level is low. Change the coolant as outlined in the Periodic Maintenance Schedule.

CAUTION

Using high-pressure water, as from a car wash facility, could damage the radiator fins and impair the radiator’s effectiveness.

Page 73

MAINTENANCE AND LUBRICATION

Polaris Variable Transmission (PVT) System

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

Do not modify any component of the PVT system. Doing so may reduce 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.

Routine maintenance is the responsibility of the owner. Always follow recommended maintenance procedures. See your dealer!

This PVT system is intended for use on Polaris products only. The PVT housing must be securely in place during operation. Failure to comply with this warning can result in severe injury or

death.

WARNING

PVT Drying

There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating.

1. Shift the transmission into neutral and apply full throttle for no longer than 10 seconds and repeat as necessary. This will expel the moisture and air dry the belt and clutches.

2. Allow the engine RPM to settle to idle speed, then shift the transmission to the lowest available range.

3. Test for belt slippage. If the belt slips, repeat the process.

4. Take the vehicle to your dealer for service as soon as possible.

Page 74

MAINTENANCE AND LUBRICATION

Vehicle Immersion

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

1. Move the vehicle to dry land, or at the very least, to a water level below the floor.

2. Disconnect the fuel pump wires.

3. Remove the spark plug.

4. Loosen the carburetor drain screw (1).

5. Turn the engine over several times with electric start.

6. Dry the spark plug and reinstall, or install a new plug.

7. Tighten the carburetor drain screw.

8. Reconnect the fuel pump wires.

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

10. Take the machine t o your dealer for s ervice as soon as possible whether you succeed in starting it or not.

NOTE: If water has been ingested into the PVT follow the procedure on page 71 for drying.

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

CAUTION

Page 75

MAINTENANCE AND LUBRICATION

Air Filter Service

We recommended that the air filter be replaced annually. When operating in extremely dusty conditions, replacement will be required more often.

1. Lift the box.

2. Remove the cover and inspect the gasket. It should adhere tightly to the cover and seal all the way around.

3. Remove the air filter. Do not attempt to clean the main element.

4. Install a new air filter. NOTE: Apply a small amount of general purpose grease t o the sealing edges of the filter before installing.

5. Check the air box. If oil or water deposits are found, drain them into a suitable container.

NOTE: Service more frequently if vehicle is operated in wet conditions or at high throttle openings for extended periods.

Page 76

MAINTENANCE AND LUBRICATION

Breather Filter and Hoses

1. Lift the box and l ocate the airbox (1).

2. Follow the righthand breather line out of the side of the airbox and locate the filter (2).

3. Remove and inspect the filter for debris. Blow gently through the filter in the direction of the arrow to check for clogging. Replace as needed.

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

5. Reinstall the filter and clamps with the arrow pointing toward the engine.

Do not perform this operation immediately after the engine has been run. The exhaust system becomes very hot and can cause severe burns.

WARNING

CAUTION

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

Page 77

MAINTENANCE AND LUBRICATION

Spark Plugs

S Use NGK BKR5E spark plugs. S Proper electrode gap is .036″ (.90 mm). S Spark plug torque is 14 ft. lbs.(19 Nm).

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

Normal Plug

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

NOTE: The tip should not be white. A white insulator tip indicates overheating, caused by an improper spark plug or incorrect carburetion adjustments.

Wet Fouled Plug

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

Page 78

MAINTENANCE AND LUBRICATION

Spark Plug Removal and Replacement

1. Remove the seat to access the engine compartment.

2. Remove the spark plug cap.

3. Using the spark plug wrench provided in the tool kit, remove the spark plug by rotating it counterclockwise.

4. Reverse the procedure for spark plug installation. Torque to 17 ft. lbs. (2.3 kg/m).

Cylinder Head/Cylinder Base F asten er Torque

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

The exhaust system or engine can cause serious burns. Always wait for the engine to cool before removing spark plugs.

WARNING

CAUTION

Always use the spark plugs recommended in this Owner’s Manual. Using the wrong plugs can cause engine damage.

Page 79

MAINTENANCE AND LUBRICATION

Spark Arrestor

The exhaust pipe must be periodically purged of accumulated carbon as follows. Use the following procedure.

Do not perform this operation immediately after the engine has been run. Exhaust system temperatures can reach 1000° F.

Because of the increased fire hazard, make sure there are no combustible materials in the area when purging the spark arrestor.

Wear eye protection. Do not stand behind or in front of the vehicle while purging the

carbon from the spark arrestor. Never run the engine in an enclosed area. The exhaust contains

poisonous carbon monoxide gas. Do not go under the machine while it is inclined. Failure to heed these warnings could result in serious personal injury

or death.

WARNING

1. Remove the arrestor clean-out plugs (1) located on the bottom of the muffler.

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 particles are still suspected to be in the muffler, 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.

NOTE: See WARNING above.

Page 80

MAINTENANCE AND LUBRICATION

Spark Arrestor (cont.)

5. If particles are 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.

NOTE: See WARNING above.

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.

Page 81

MAINTENANCE AND LUBRICATION

Throttle Pedal

Throttle Freeplay

If the throttle pedal (1) has excessive play due to cable stretch or cable misadjustment, it will cause a delay in throttle response, especially at low engine speed. The throttle may also not open fully. If the throttle pedal has no play, the throttle may be hard to control, and the idle speed may be erratic. Check the throttle pedal play periodically as outlined in the Periodic Maintenance Schedule. Adjust the play if necessary.

Throttle Fr eeplay Inspection

1. Apply the parking brake (2).

2. Put the gear shift lever in the neutral position.

3. Start the engine and warm it up thoroughly.

4. Measure the distance the throttle pedal moves before the engine begins to pick up speed. Freeplay should be 1/16 to 1/8 inches.

Adjustment

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

2. Turn the adjuster until 1/16 to 1/8 inch freeplay is achieved.

NOTE: While adjusting freeplay, you must flip the throttle lever back and forth.

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

Page 82

MAINTENANCE AND LUBRICATION

Carburetor/Engine Idle RPM Adjustment

The idle speed adjustment should be performed as outlined in the Periodic Maintenance Schedule, or whenever the idle speed is changed.

Recommended engine idle RPM is 1200 +/- 200. If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted with the following procedure.

1. Apply the parking brake.

2. Place the gear shift lever in the neutral position.

3. Warm up the engine by running the vehicle approximately five minutes.

4. Remove the the seat and locate theidlescrew(1).

5. Place the transmission in gear (with the parking brake applied.)

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

Page 83

MAINTENANCE AND LUBRICATION

Brakes

Front and Rear Brake In sp ectio n

The front and rear brakes are hydraulic disc type brakes and are activated by the brake pedal. See page 43.

Routine inspections are recommended to keep the brake system in good operating condition. Inspect the level of the brake fluid before each operation.

Change the brake fluid as outlined in the Periodic Maintenance Schedule. The brake fluid should also be changed if it becomes contaminated with dirt or water.

Inspection Procedure:

1. Position the vehicle on level ground.

2. Inspect the brake fluid by looking at the reservoir (1) under the hood. The level should be between the upper (MAX) and lower (MIN) level lines.

3. If the fluid level is lower than the lower level line, add brake fluid to the upper (MAX) line.

4. Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings.

CAUTION

Change the fluid in the brake system completely if the fluid level is below the minimum, or if the type and brand of the fluid already in the reservoir are unknown.

Once a bottle of brake fluid is opened, use what is necessary and discard the rest. Do not store or use a partial bottle of 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.

Page 84

MAINTENANCE AND LUBRICATION

Brakes

Front and Rear Brake In sp ectio n

Check brake system for fluid leaks. Check brake for excessive travel or

spongy feel. Check friction pads for wear, damage and

looseness. Inspect the brake disc spline and pad wear

surface for excessive wear. Change pads when worn to 3/64″ (.1 cm),

about the thickness of a dime.

Brake Lig ht Insp ectio n

When the brake pedal is depressed, the console brake light comes on. Check the brake light before each ride.

1. Turn the ignition switch to the ON position.

2. Depress the brake pedal. The brake light should come on after about 10mm (0.4 in.) of pedal travel. If the light doesn’t come on, check the bulb.

3/64″ (.1 cm)

If the brake pedal has a “spongy” feeling when applied, there may be air in the brake lines, or the brake may be defective. Do not operate the vehicle under these conditions. Have the brake system serviced by an authorized Polaris dealer immediately.

WARNING

Headlight and taillight lenses may become dirty. Wash frequently to maintain lighting quality. Poor lighting while operating can result in severe injury or death.

WARNING

CAUTION

Do not service while lights are hot. Serious burns may result.

Page 85

MAINTENANCE AND LUBRICATION

Brakes

Parking Brake Inspectio n

1. Slowly push the parking brake down with your foot.

2. After 8 to 12 clicks of lever travel, check the vehicle for movement. The vehicle should not roll while parked. If the vehicle moves, adjustment is necessary

Parking Brake Adjustment

1. Place the vehicle in neutral on a flat level surface.

2. Carefully lift the rear of the vehicle off the ground and stabilize on jack stands.

3. Loosen the locknut on the rear caliper adjustment bolt.

4. Tighten the adjustment bolt until the rear tire will not rotate.

5. Back the adjustment bolt out 1/4 turn.

6. Tighten the jam nut while holding the adjustment nut in place.

7. Repeat this procedure on t he other rear tire.

Page 86

MAINTENANCE AND LUBRICATION

Steering Wheel Inspection

Check the steering wheel for specified freeplay and smooth operation as outlined in the Periodic Maintenance Schedule.

1. Park the vehicle on level ground.

2. Lightly turn the steering wheel left and right.

3. There should be 0.8 - 1.0 in (20 - 25 mm) of free play.

4. If there is excessive freeplay or strange noises, or the steering feels rough or “catchy,” have the steering system inspected by an authorized Polaris dealer.

Rear Spring Adjustment

The rear shock absorber springs are adjusted by rotating the adjustment cam (1) i n the direction required to increase or decrease spring tension.

Page 87

MAINTENANCE AND LUBRICATION

Seat Belts

Inspect all three seat belts for proper operation before each use of the vehicle.

1. Push the latch plate into the buckle until it clicks. The latch plate must slide smoothly into the buckle. A click indicates that it’s securely latched.

2. Push the red button in the middle of the buckle to make sure it releases freely .

3. Check the belt webbing for wear, cuts or damage. If any irregularities are found, have the seat belt system checked and/or replaced by an authorized Polaris dealer.

The UTV seat belt is adjustable and should be adjusted for both the operator and passenger before driving. Although having the belt at 30° is typical for many people, it will not accommodate all body sizes and shapes. Make sure the

seat belt is adjusted to the lowest possible lap position before riding.

1. To adjust, loosen the bolts (1).

2. Reposition both the buckle and retractor. Tighten bolts.

NOTE: The center belt does not self adjust. Before riding, pull on the strap to secure the belt on the lap of the center passenger.

Riding as a passenger in this vehicle is not safe for anyone under the age of five. Do not allow anyone under five to ride as a passenger. Serious injury or death could result.

WARNING

Page 88

MAINTENANCE AND LUBRICATION

Tires

Tire Tread Depth

Always replace tires when tread depth i s worn to 1/8″ (.3 cm) or less.

Axle and Wheel Nut Torque Specifications

Inspect the following items occasionally for tightness, and if they’ve been loosened for maintenance service.

Front Spindle Nut(s) Dealer Performed Service

Front Wheel Nuts 35 ft. lbs.

Center and Rear Hub

Retaining Nut(s)

120 ft. lbs.

Rear Wheel Nuts 35 ft. lbs.

Operating your vehicle with worn tires will increase the possibility of skidding, loss of control, and an accident.

Always replace tires when the tread depth measures 1/8″ (.3 cm) or less.

WARNING

CAUTION

Always maintain proper tire pressure. Improper tire inflation may affect vehicle maneuverability.

When replacing tires, always use original equipment size and type. The use of non-standard size or type tires may adversely affect vehicle handling.

1/8I (.3 cm)

Page 89

MAINTENANCE AND LUBRICATION

Wheels

Wheel Removal

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

2. Loosen the wheel nuts slightly.

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

4. Remove the wheel nuts and washers. Remove the wheel.

Wheel Installation

1. With the transmission in gear and the parking brake locked, place the wheel in the correct position on the wheel hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation.

2. Attach the wheel nuts and washers and finger tighten.

3. Carefully lower the vehicle t o the ground.

4. Torque the wheel nuts according to the specifications on page 86.

CAUTION

If wheels are improperly installed, you may experience an adverse effect on vehicle handling and/or tire wear. Both could lead to loss of control, overturn, and injury.

Page 90

MAINTENANCE AND LUBRICATION

Lights

Headlight Beam Adjustment

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

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

3. Start the engine and switch on the headlight.

4. Observe the headlight aim. The most intense part of the headlight beam should be aimed 8″ (20.3 cm) below the mark placed on the wall in step 2. NOTE: Include the weight of a rider on the seat while performing this step.

5. Adjust beam to desired position by turning adjustment screws (1) in headlight cover as follows: Turn the right screw clockwise to adjust to the left. Turn the left screw clockwise to adjust to the right. Turn the bottom s crew clockwise to adjust upward.

Page 91

MAINTENANCE AND LUBRICATION

Lights

Indicator Lamp Replacement

1. Lift the hood.

2. Reach in behind the dash panel and lift the release (1) to unplug the light from the harness.

3. Using a flathead screwdriver, press on the tab (2) on the top of the light to remove the indicator light assembly from the dash panel.

4. Using a screwdriver, turn the light that needs to be replaced 1/4 turn counterclockwise.

5. Grip the light with a needle nose plier and remove the light from the assembly.

6. Install the new light and use a small flat head screwdriver to seat it into place, 1/4 turn clockwise.

7. Snap the assembly back into the dash panel and reconnect the harness.

8. Close the hood.

Tool Kit

To help you perform routine maintenance, a tool kit is provided with your vehicle. Items included in the kit are:

S A screwdriver S An open-end wrench (8-10 mm) S An open-end wrench (12-14 mm) S A tire pressure gauge S A spark plug wrench and handle

NOTE: Additional tools will be necessary to perform routine maintenance.

Page 92

MAINTENANCE AND LUBRICATION

Cleaning Your UTV

Keeping your vehicle clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your vehicle can be cleaned much like an automobile.

The best and safest way to clean your vehicle is with a garden hose and a pail of mild soap and water. Use a professional type washing mitten, cleaning the upper body first and the lower parts last. R inse with water frequently and dry with a chamois to prevent water spots. NOTE: If warning labels are damaged, contact your Polaris dealer for free replacement.

If a high pressure type car wash system is used, extreme care must be taken to avoid water damage to the wheel bearings, transmission seals, body panels, brakes, headlights and warning labels. Many expensive repair bills can result from using high pressure detergent systems.

NOTE: If a high pressure car wash is used, grease all zerk fittings immediately after washing. Also run the vehicle to evaporate any water that may have entered the engine or exhaust system.

Page 93

MAINTENANCE AND LUBRICATION

Storage

If your vehicle is to be placed in extended or off season storage, the following steps should be taken to preserve its condition.

1. Perform all necessary repairs and thoroughly clean the vehicle.

2. Remove the spark plug and pour approximately one ounce of Premium 4 oil into the cylinder. Operate the starter for a few seconds and reinstall the spark plug.

3. Remove the battery. Store it in a cool, dry place out of the sun.

4. Lubricate s uspension pivot points, lower steering post and rear axle fittings.

5. Drain the engine side cover.

6. Block the vehicle so all tires are suspended off the ground.

7. Spray oil on all unpainted metal surfaces to prevent rusting. Avoid getting oil on rubber parts or in the brakes.

8. Lubricate all cables.

9. Tie a plastic bag over the exhaust pipe and air cleaner inlet to prevent moisture or small animals from entering.

10. Cover the vehicle with a canvas cover. Do not use plastic or coated materials since they do not allow ventilation for the vehicle.

Page 94

MAINTENANCE AND LUBRICATION

Removal from Storage:

1. Check the battery electrolyte level and charge the battery if necessary. Install it in the vehicle. Make sure the battery vent hose is routed properly and that it’s not pinched or restricted in any way.

2. Make sure the spark plug is tight.

3. Fill the fuel tank with fuel.

4. Check all the points listed in the Daily Pre-Operation Inspection section beginning on page 47.

NOTE: Tightness of the bolts, nuts and other fasteners should be checked by an authorized Polaris dealer.

5. Lubricate as outlined in the Periodic Maintenance Schedule.

Do not run the engine in a closed area. Exhaust gases contain carbon monoxide; a colorless, odorless, poisonous gas. Breathing exhaust gas leads to carbon monoxide poisoning, asphyxiation and death.

WARNING

Page 95

MAINTENANCE AND LUBRICATION

Battery

Replenishing 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 (1).

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 water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly.

CAUTION

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

CAUTION

Use only distilled water when refilling a battery. Tap water contains minerals that are harmful to a battery.

Allowing cleaning solution or tap water to enter the battery will shorten the life of the battery.

CAUTION

Vehicle lamps may burn out if the battery is disconnected during vehicle operation. The reverse speed limiter may also be damaged.

Page 96

MAINTENANCE AND LUBRICATION

Battery

Battery Removal

1. Remove the seat to access the battery.

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 vehicle, being careful not to tip it sideways and spill any electrolyte.

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.

WARNING

Page 97

MAINTENANCE AND LUBRICATION

Battery

Battery In stallation

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 as severe burns could result.

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

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

5. Verify that cables are properly routed.

NOTE: When your UTV 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. Before reusing, take the battery to your dealer for testing and recharging.

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 UTV.

To avoid the possibility of explosion, always connect battery cables in the order specified. Red (positive) cable first; black (negative) cable last.

WARNING

Page 98

SPECIFICATIONS

UTV2X4 UTV4X4 Gross Vehicle Weight 2500 lbs. 2700 lbs. Fuel Capacity 8.0 Gallons 8.0 Gallons Towing Capacity 1400 lbs. 1500 lbs. Maximum Cargo Box Load 850 lbs. 1000 lbs. Overall Length 113 in. 113 in. Overall Width 58 in (tires) 60 in (box) 58 in (tires) 60 in (box) Overall Height 74 in. 75 in. Wheelbase 76 in. 76 in. Ground Clearance 5.8 in. 7in. Dry Weight 1196 lbs. 1263 lbs. Cargo Box (L x W x H) 58 x 46 x 10 in. 58 x 46 x 10 in. Minimum Turning Radius 132 in. 132 in. Engine Oil Capacity 2qts. 2qts. Coolant Capacity 2.25 qts. 2.25 qts. Engine 4valve4strokesingle

cylinder with counter

balance

4valve4strokesingle cylinder with counter

balance Displacement 425 cc 499 cc Bore x Stroke 87.9 x 70 92 x 75 Pilot Jet 42.5 42.5 Main Jet 135 142.5 Needle Jet P-6 (829) P-6 (829) Jet Needle 4LC38-3 4MB32-3 Air Screw 21/4 21/2 Alternator Output 250 W 250 W Compression Ratio 9.2 10.2:1 Starting System Electric Electric Carburetor 34 mm - CV Mikuni 34 mm - CV Mikuni Ignition System CDI CDI Ignition Timing 30_ @ 5000 rpm 30_ @ 5000 rpm Spark Plug NGK BKR5E NGK BKR5E

Page 99

SPECIFICATIONS

UTV2X4 UTV4X4 Lubrication System Dry Sump Dry Sump Engine Oil 0W/40 0W/40 Driving System Type PVT PVT Shift Type Single Lever on dash Single Lever on dash Gear Reduction - Low 8.6:1 8.6:1 Gear Reduction - Reverse 5.9:1 5.9:1 Gear Reduction - High 4.6:1 4.6:1 Drive Ratio - Front: NA 3.83:1 Drive Ratio - Final 3.70:1 3.70:1 Tire Size - Front 23 x 8.5 - 12 (Turf) 25 x 10 - 12 Tire Size - Rear 23 x 10 - 12 (Turf) 25 x 11 - 12 Tire Pressure - Front 10 psi 10 psi Tire Pressure - Rear 10 psi 10 psi Brake Foot Activated, 4 Foot Activated, 4

BrakeFootActivated,

wheel hydraulic disc

FootActivated,4

wheel hydraulic disc

Front Hydraulic disk, float-

ing caliper

Hydraulic disk, floating caliper

Rear Hydraulic disk, float-

ing caliper with me-

chanical parking

brake

Hydraulic disk, floating caliper with mechanical parking brake

Parking Brake Foot activated

mechanical

Foot activated mechanical

mechanicalmechanica

Hood Headlight (watts) 2 dual beam - 35W -

quartz / halogen

2 dual beam - 35W -

quartz / halogen Taillights (watts) 2 single beam, 5W 2 single beam, 5W Brake Light (watts) 2 single beam, 5W 2 single beam, 5W Indicator Light (watts) 1.0 1.0

Page 100

TROUBLESHOOTING

ENGINE CRANKS BUT FAILS TO START

No Fuel Water in Fuel Spark Plug

Drain System

No Spark to

Spark Plug

Contact Your

Dealer

ENGINE STOPS OR LOSES POWER

No Fuel

Contact Your

Dealer

Contact Your

Dealer

Overuse of

Choke

Spark Plug

Fouled

Engine

Overheated

Clean Engine

Exterior

Water in Fuel

Air Filter Clogged

Fuel Vent Line

Kinked or

Plugged

Clean Radiator

screen

Fuel Pump

Faulty

Contact Your

Dealer

Plugged fuel

line or fuel

filter