Polaris 2000 Universal ATV Owner's Manual PDF

Pages 133
Year 2000
Language(s)
English en
1 of 133
1 of 133

Summary of Content for Polaris 2000 Universal ATV Owner's Manual PDF

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

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Never operate an ATV without proper instruction... Take a training course... Be- ginners should receive training froma certified instructor... Contact an authorized Polaris ATVdealer or call Polaris at 1-800-342-3764 to find outabout the training courses nearest you...

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

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

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To order PRO merchandise, complete the order form you receive with your mem- bership packet, take the form to your Polaris dealer and pay for the merchandise... Themerchandisewill be shipped directly to your home from the PROmerchandise fulfillment center... Watch for your PRO membership packet and the next issue of PRO Spiritmaga- zine... This quarterly magazine will keep you informed about Polaris news and events, and special PRO merchandise, travel, and ride opportunities...

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

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KNOW YOUR VEHICLE BEFORE YOU BEGIN RIDING! Read this manual thoroughly referring to the various areas which are being dis- cussed on your machine... Operating this vehicle carries with it responsibilities for your personal safety, the safety of others, and the protection of our environment...

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

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NOTE: Warning decals have been placed on the vehicle for your protection... Read and follow the instructions on each decal carefully... In the event any decal becomes il- legible or comes off, contact your Polaris dealer for a replacement... Any safety de- cal needing replacementwill be provided byPolaris at no charge... The part number is printed on the decal...

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HILL CLIMBING IS DANGEROUS, and should be attempted only by experienced operators... Start on shallow slopes and practice procedures described in Owners Manual before trying steeper terrain... Some hills are too steep to safely stop or recover from an unsuccessful climbing attempt... Effectiveness of brakes is significantly reduced on hills...

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

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Correct loading of this vehicle is necessary to maintain proper stability and operating char- acteristics... Overloading or incorrect positioning of the load effects the vehicles turning, stopping distance and stability... Failure to follow loading requirements could cause severe injury or death... REDUCE SPEED AND ALLOW GREATER DISTANCE FOR BRAKING WHEN CARRYING CARGO... CARGOWEIGHT DISTRIBUTION should be 1/3 on the front rack and 2/3 on the rear rack... When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driv- ing conditions... Maximum cargo capacity is 270 lbs... on level terrain... When operating at maximum cargo capacity, the cargoweight distributionmust be90 lbs... on the front rack and 180 lbs... on the rear rack... ALL LOADS MUST BE SECURED BEFORE MOVING VEHICLE... Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle... LOADS MUST BE CARRIED AS LOW ON THE RACKS AS POSSIBLE... Carrying loads high on the racks raises the center of gravity of the vehicle and creates a less stable operat- ing condition... When cargo loads are carried high on the racks, the weight of the loadsmust be reduced to maintain stable operating conditions... OPERATE ONLYWITH STABLE AND SAFELY ARRANGEDLOADS... When handling off- centered loads which cannot be centered, securely fasten load and operate with extra cau- tion... EXTREME CAUTIONMUST BE USED when operating with loads extending over the rack sides... Stability and maneuverability may be adversely affected, causing the machine to overturn... DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the front rack...

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

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ATTENTION DOPERATION OF THIS VEHICLE WITHOUT THE FILTER ELEMENT WILL SEVERELY DAMAGE THE ENGINE...

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

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

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

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Beginning and inexperienced operators should complete the certified training course offered by Polaris Industries Inc... They should then reg- ularly practice the skills learned in the course and the operating tech- niques described in the Owners Manual...

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

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

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

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Operating without eye protection can result in an accident and in- creases your chances of a severe injury in the event of an accident...

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

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Never attempt stunts, such aswheelies or jumps... Dont try to showoff...

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Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off the ATV... If you remove a foot from the footrest, your foot or leg may come into contactwith the rearwheels,which could injure you or cause anacci- dent...

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

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

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

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Never go over the top of any hill at high speed... An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill...

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

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Never attempt to turn the ATV around on any hill until you have mas- tered the turning technique as described in the Owners Manual on level ground... See page 68... Be very careful when turning on any hill...

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If you begin rolling backwards: Keep weight uphill; never apply engine power... Never apply the rear brake while rolling backwards... Apply the single-lever brake gradually... When fully stopped, apply rear brake as well, and then lock parking brake... Dismount on uphill side, or to either side if pointed straight uphill... Turn the ATV around and remount, following the procedure described in the Owners Manual... See page 68...

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POTENTIAL HAZARD Improperly operating over obstacles... WHAT CAN HAPPEN Could cause loss of control or a collision... Could cause theATV to overturn... HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles... Use extreme caution when riding over large obstacles, such as large rocks or fallen trees... If you cannot avoid obstacles, always follow proper procedures as de- scribed in the Owners Manual...

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

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

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

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The vehicle frame and engine serial numbers are important formodel identifica- tion when registering your vehicle, obtaining insurance or whenever replace- ment parts are required... In the event your vehicle were stolen these numbers are essential to the recovery and identification of your ATV...

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1... Override Switch (Reverse Speed Limiter) - This vehicle is equipped with a re- verse speed limiter system... To obtain additional power while backing up, depress the override button... WARNING: Never activate the override button while throttle is open as loss of control may result, causing severe personal injury or death... NOTE: The override switch also allows activation of Demand 4 Drive (All Wheel Drive) in reverse, if Demand 4 Drive switch is on... 2... Main Switch - This switch must be turned clockwise to the on position to start the engine... 3... Emergency Engine Stop Switch - The engine will not start or run when the switch is in its off position... Its purpose is to provide the operator with a quick means of engine shutdown in case of stuck throttle or other emergency... NOTE: Both the main switch and the emergency engine stop switch shut off all electrical power to the entire vehicle including lights... To stop the engine, slide the stop switch right or left to the off position... 4... Engine Start Button - Slide the stop switch to the center run position and push up to start...

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Each Polaris ATV has indicator lights... The configuration of these lights differs with individual models and not every model is equipped with all the lights... The informa- tion in yourOwnersManualSupplement and in the following boxwill help you iden- tify the lights on your machine and their function...

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

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Engine speed and vehicle move- ment are controlled by pressing the throttle lever... The throttle lever is spring loaded and engine speed re- turns to idle when the lever is re- leased... This vehicle is equipped with a Polaris Electronic Throttle Control (ETC) which is designed to reduce the risk of a frozen or stuck throttle... In the event the throttle cable should stick in an open posi- tion, the engine will stop and power to the rear wheels will cease when the operator releases the throttle le- ver...

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

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

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

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The transmission gear selector is located on the right side of the vehicle directly above and forward of the engine recoil starter... The transmission selector lever has three or four positions: high forward; re- verse; neutral; and low forward or forward; reverse; and neutral... Check your Owners Manual Supplement for specification...

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Exclusive Demand 4 Drive System (All Wheel Drive) Polaris 4wheel drive ATVs are equipped with a unique,Polaris exclusive,Demand 4 Drive (AWD) systemwhich is activated by a switch on the right handlebar... When the switch is off the 4x4 is in 2 wheel drive at all times... When the switch is on the 4x4 is in Demand 4 Drive and the front wheels will automatically engage any- time the rear wheels lose traction... When the rear wheels regain traction, the front wheels will automatically disengage... NOTE: The override switch also allows ac- tivation of Demand 4 Drive (AWD) in reverse, if Demand 4 Drive switch is on...

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WARNING The PVT system rotates at high speeds, creating large amounts of force on clutch components... Extensive engineering and testing has been con- ducted to insure the safety of this product... However, as the owner you have the following responsibilities to make sure this system remains safe: DDo not modify any component of the PVT system... Doing so may re-

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NOTE: Some coolant level drop on new machines is normal as the sys- tem is purging itself of trapped air... Observe coolant levels and maintain as recommended by adding coolant to the recovery bottle... Polaris recom- mends 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 dilutewithwater... NOTE: Always follow themanufacturers mixing rec- ommendations for the freeze protection required in your area...

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Engine Cooling System To insure that the coolant maintains its ability to protect the engine, it is recom- mended that the systembe completely drainedevery twoyears anda freshmixture of antifreeze and water be added... Polaris recommends the use of Polaris Pre- mium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum com- patible anti-freeze/coolant and distilled water... NOTE: Polaris Premium 60/40 is already premixed and ready to use... Do not dilute with water... IMPORTANT: Al- ways follow the manufacturers mixing recommendations for the freeze protection required in your area...

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On models with a two cycle engine, the engine oil injection tank filler cap (2) is lo- cated on the front of the machine... Refer to you Owners Manual Supplement to determine the type of engine your vehicle has... The tank capacity is 2 quarts (1... 9 l)... CAUTION: To avoid serious engine damage always top off the oil level when refueling...

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DNever start the engine or let it run in an enclosed area... Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time...

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Oil and Filter Change The recommended oil change interval is 100 hours, 1000 miles, or every six months, whichever comes first... Suggested break in oil change is at 20 hours, 500 miles, or one month, whichever comes first... Severe use operation requires more frequent service... Severe use includes continuous duty in dusty or wet conditions, and cold weather riding... NOTE: Severe use cold weather riding is all riding below 10 F, and riding between 10 F and 30F whenmost trips are slow speed and less than 5 miles... Be sure to change the oil filter whenever changing oil 1... Place vehicle on a level surface... 2... Clean area around drain plug which is found at the bottom of the oil tank or on

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

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These filters should be replaced by your dealer after every 100 hours of operation or annually... Do not attempt to clean these filters...

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CAUTION: Engine warranty coverage may become void if other brands are substituted... Polaris Premium 2-cycle lubricants are the most advanced formulation of oils spe- cifically designed for todays 2-cycle engines... Months of lab and field tests have resulted in a new generation of 2-cycle lubricants... Polaris Premium 2-cycle lubri- cants provide additives for 2-cycle engines lacking in todays fuel that keep ring grooves cleaner for less ring sticking and provide improved overall engine cleanli- ness... With new generation lubricity technology, they excel in meeting the lubrica- tion demands of todays high performance 2-cycle engines... These are optimum oils recommended for liquid cooled and air cooled 2-cycle engines... We believe these oils are the best available in the market today...

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If the battery is weak and cannot start the engine, use of the recoil starter located on the right side of the machine will allow vehicle operation until repairs can be made... Polaris 4-cycle engines are equipped with automatic decompressors... Thismakes recoil starting possible by allowing compression to leak at cranking speeds... The decompressor senses when the engine is spinning fast enough to start and re- stores compression for starting... 1... Be certain your vehicle is on a level surface and the parking brake is set ... See

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CAUTION: Make sure the manual start handle is fully seated on the recoil housing, especially when travelling in wet areas... If it is not sealed properly, water may enter the recoil housing and damage components... Water will enter the recoil housing if the starter handle is disengaged from the rope guide when under water... After travelling in wet areas the recoil housing and starter should always be drained completely by removing the recoil... Do not open the crankcase drain unless the engine has ingested water... On 4-cycle engines, some engine oil will be lost if crankcase drain is opened... On the Trail Blazer, the recoil handlemust be behind the heat shield for it to seal properly... If it is not sealed properly, water may enter the recoil housing and dam- age components...

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9... Press starter button for five seconds... If engine does not start, release starter but- ton and wait five seconds; then press starter button for another five seconds... Repeat this procedure until engine starts...

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2-Cycle Engines The break in period for your new Polaris ATV is defined as the time it takes to use the first tank of gasoline... No single action on your part is as important as a proper break in period... Careful treatment of a new engine will result in more efficient per- formance and longer life for the engine... Perform the following procedurescarefully...

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4-Cycle Engines The break in period for your new Polaris ATV is defined as the first ten hours of op- eration, 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... Per- form the following procedures carefully...

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2... Eye Protection Do not depend on sunglasses for proper eye protection... A pair of goggles or hel- met face shield offer the best protection for your eyes... They should be kept clean and be of shatterproof design (bearing the markings z2... 1 or VESC 8)...

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Your ATV has been designed to carry a certain amount of load... CARGOWEIGHT should be evenly distributed (1/3 on the front and 2/3 on the rear) and mounted as low as possible... When operating over rough or hilly terrain, reduce speed and car- go to maintain stable driving conditions... Never exceed the weights specified in your Owners Manual Supplement...

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

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

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5... Slowly depress the throttle with your right thumb and begin driving... Vehicle speed is controlled by the amount of throttle opening and all transmission shift- ing is done automatically...

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

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Whenever riding on slippery surfaces such as wet trails or loose gravel, or during cold freezing weather, special attention must be paid to prevent vehicle turnover... Always: 1... Slow down when entering slippery areas... 2... Maintain a high level of alertness, reading the trail and avoiding quick, sharp

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Loss of vehicle control or overturning of the ATV could occur... DAvoid operating on steep hills (25_ maximum)...

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Sidehilling your ATV is one of the most dangerous types of riding and should be avoided if possible... In the event you do enter into a situation where sidehilling is necessary, always: 1... Slow down...

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

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If theATVstallswhile climbing ahill, neverback itdown thehill! One maneuver which can be used when it is necessary to turn around while climbing a hill is the K-turn... 1... Stop and lock the parking brake while maintaining body weight uphill... 2... Leave transmission in forward and shut off engine... 3... Dismount on left or uphill side of ATV... 4... Staying uphill of ATV, turn handlebars full left (while facing front of ATV)... 5... While holding service brake, release parking brake lock and slowly allow ATV

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

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Keep Alert! Look ahead and learn to read the trail as you ride... Stay on the right side of the trail, if possible, and be constantly alert for hazards such as logs, rocks and lowhanging branches...

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

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

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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 offwith clean rags... Coat the terminals with dielectric grease or petro- leum jelly...

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Battery Installation WARNING: To avoid the possibility of explosion, always connect battery cables in the order specified... Red (positive) cable first; black (negative) cable last... 1... Set the battery in its holder... 2... Install the battery vent tube... It must be free from obstructions and securely

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(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 incorpo- rated into any newvehicle for the purposeof noisecontrol prior to its sale ordelivery to the ultimate purchaser or while it is in use or

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5... If particles are still suspected to be in themuffler, 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 themachine is in neutral and repeat steps 2 and 3... WARNING: SEE BELOW...

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DBecause of the increased fire hazard, make sure that there are no com- bustible materials in the area when purging the spark arrestor...

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Power Pig Tail Some models are equipped with an auxiliary power outlet... Refer to your Owners Manual Supplement to determine if your machine has one...

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

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JL Fuel System 100 hours 12 months Check for leaks at tank cap, lines, fuel valve, filter, pump and carburetor... Re- place lines every two years...

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

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Remove set screw in hubs... Ro- tate wheels to 4 Oclock position... If lubricant is not visible add more... Reinstall set screw...

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

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Periodic Maintenance Record Use the following chart to record periodic maintenance work:

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

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Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component op- erations... Service work must be performed by your authorized Polaris dealer...

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Rear Spring Adjustment The rear shock absorber spring is adjusted by rotating the adjuster in the direction required to increase or decrease spring tension...

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

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Cleaning the Main Filter Important: It is advisable to replace the filter when it is dirty... However, in an emergency it is permissible to clean the main filter if you observe the following practices... 1... Never immerse the filter in water since dirt can be transferred to the clean air side

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CAUTION: When installing the pri- mary air filter box be sure the gray foam collar (B) is below the intake opening of the air box intake (A)... Improper installation will restrict air- flow to the engine possibly resulting in engine damage...

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6... Reinstall filter into air Box and tighten clamp... Do not over tight- en clamp or filter damage may occur...

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2... Inspect filter for debris... Blow through gently in direction of arrow on filter to check for clogging... Replace as needed...

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You can check the toe align- ment of the vehicle using the fol- lowing method... The recom- mended toe alignment is 1/8 to 1/4 (... 3 to ... 6 cm) toe out... If you discover improper adjustment have your dealer correct it... 1... Set the handlebars in a straight ahead position and hold them in this position... NOTE: The steering frog can be used as an indicator of whether the handlebars are straight... The frog should always point straight back from the steering post...

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level marks at all times... Normal functioning of the diaphragm is to extend into the reservoir as fluid level drops... If the fluid level is low and the dia- phragm is not extended, a leak is indicated and the diaphragm should be replaced... Always fill the reservoir as indicated whenever the cover is loos- ened or removed to insure proper diaphragm operation... Use Polaris DOT 3 brake fluid (PN 2870990)...

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Auxiliary Brake Systems Your ATVs auxiliary brake system is intended to be used as a backup for the main brake system... Should themain system fail, the rear brake can be activated by de- pressing the foot pedal on the inside of the right floorboard... All Polaris ATVs have hydraulic brake systems... The hydraulic auxiliary brake systemwill not require ad- justment...

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2... Loosen throttle cable jam nut and turn adjuster in or out until there is 1/16 - 1/8 (... 16 - ... 32 cm) of throttle lever trav- el before throttle slide starts to open... See Owners Manual Supplement...

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2... Loosening the bleeder screw is only necessarywhen theoil supply line hasbeen disconnected from the pump or the oil reservoir and supply line have been completely run out of oil... In these cases, loosen the pump bleed screw one full turn... Allow oil to flow from the bleed screw for five to ten seconds... Tighten bleed screw... CAUTION: Never run the engine with the bleed screw loose... Loss of oil will cause serious engine damage...

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Engine Choke Adjustment 2-Cycle Engines With the dash mounted choke control toggle flipped to full off position, the choke plunger must be seated on the fuel passageway in the carburetor... If the plunger is not seated on the passageway, the enginewill flood or run too rich, causingspark plug fouling and very poor engine performance...

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Carburetor/Engine Idle RPM Adjustment 2 Cycle Engines If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted as follows: 1... Warm up the engine by running

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Carburetor/Engine Idle RPM Adjustment 4-cycle Engines If the engine idle speed is not satis- factory, and all other conditions are favorable, the carburetor can be ad- justed as follows: 1... Warm up the engine by running the

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2... Wet Fouled 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 notworn... General causes are excessive oil, use of non-recommended injection oil, improper use of the choke, or incorrect carburetion adjustments...

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The transmission lubricant level should bechecked every sixmonthsor 1000miles (1600 km), whichever comes first... Transmission oil should be changed annually... With the ATV on a level surface, remove fill plug and check the lubricant level... Lu- bricant level is correct when it reaches the bottom of the filler hole... The correct transmission lubricant to use is Polaris Premium Synthetic Gearcase Lubricant (PN 2871478)...

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The transmission lubricant level should be checked monthly or 1000 miles (1600 km), whichever comes first... Transmission oil should be changed annually... With the ATV on a level surface, remove fill plug dipstick and check the lubricant level... Lubricant should be kept at the full mark on the dipstick... The correct transmission lubricant to use is Polaris Premium Synthetic Gearcase Lubricant (PN 2871478)...

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The front gearcase lubricant level should be checked every six months or 1000 miles (1600 km), whichever comes first... Front gearcase oil should be changed annually... With the ATV on a level surface, remove fill plug and check the lubricant level... Lubricant should be kept at the bottom of fill plug thread... The correct gearcase lubricant to use is GL5 80-90 Weight Gear Lube...

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Counter Balance Lubrication 400 Engines The counter balance oil should be checked semi-annually and oil should be added or changed as necessary... The oil should be changed annually, especially be- fore off season storage... If the ma- chine is used in wet conditions the oil should be checked more fre- quently... If the oil has a milky ap- pearance it should be changed as soon as possible... Failure to prop- erly maintain this important area can result in premature wear or possible failure of the counter bal- ance components... Always use SAE 10W30 oil...

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the correct position on the wheel hub... Be sure the valve stem is toward the out- side and rotation arrows on the tire point toward forward rotation...

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Tire Tread Depth Always replace tires when tread depth is worn to 1/8 (... 3 cm) or less... Please refer to your Owners Manual Supplement for tire specifications...

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MAINTENANCE Drive Chain Inspection and Adjustment Polaris ATV drive chains are equipped with O-ring sealed permanently greased pins and rollers... However, it is still necessary to lubricate the outer surfaces of the roller...

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Check the amount of chain slack by moving the vehicle slightly forward to gain slack at the top side of the rear chain... At this point the chain should have3/16-3/8 (... 48 cm - ... 95 cm)deflection... If the chain needs adjustment, use the followingproce- dure...

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WARNING: Due to the nature of ATVs and where they are ridden, headlight and taillight lenses become dirty... Frequent washing is necessary to maintain light- ing quality... Poor lighting while riding can result in severe injury or death... CAUTION: Do not service while headlight is hot... Serious burns may result...

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5... Adjust beam to desired position by turning adjustment screws in headlight cover... Turning right screw clockwise moves the intense spot of light up to the left... Turning the left screw clockwise moves intense spot of light up to the right... Turning the bottom screw clockwise adjusts the light upwards...

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5... Disengage the tabs at the front of the upper panel where they snap into the lower panel surrounding the headlight assembly... Alsodisengage the tabs on the upper panel which engage with the lower triangular panels on either side of themachine... Lift off the upper panel and set it aside...

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High Beam Headlight Adjustment The headlight beam can be adjusted to any position desired by turning the four screws at the outer corners of the lamp housing... 1... Place the vehicle on a level surface with the headlight approximately 25 (7... 6 m) from a wall...

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High Beam Headlight Adjustment The headlight beam can be adjusted to any position desired by turning the adjust- ing knob located on the bottom right side of the headlight pod... 1... Place the vehicle on a level surface with the headlight approximately 25 (7... 6 m) from a wall...

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NOTE: To aid in accessing these screws, it may be helpful to turn handlebars to left or right and use a short, stubby screwdriver... Removal of the front rack and cover may also allow easier access...

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Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work the lamp may need to be replaced...

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

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Carburetor Adjustments If the vehicle is to be operated at variousaltitudes and temperatures, certainadjust- ments can be made to improve its operation and driveability... Above 6000 feet (1800m) the engine air/fuelmixture becomes overly rich... An engine loses approxi- mately 3%of its power for each 1000 foot (304... 8m) increase inelevation... Although this power cannot be regained, changes to the carburetor and drive system can be made to allow efficient operation... These changes include: 1... Carburetor re-jetting to compensate for altitude and/or temperature changes...

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Procedures The following information is provided to help you identify probable causes forques- tions you may have about the operation of your ATV... See your Polaris dealer with any additional questions you may have...

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REGISTRATION At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days... Upon receipt of this registration, Polaris will record the registration for warranty... THE PURCHASER MUST COM- PLETE AN ATV SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE ATV... No verification of registra- tion will be sent to the purchaser as the copy of theWarrantyRegistration Formwill be the warranty entitlement... If you have not signed the original registration and re- ceived the customer copy, please contact your dealer immediately... NO WAR- RANTY COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REG- ISTERED WITH POLARIS... Initial dealer preparation and set--up of your ATV is very important in ensuring trouble--free operation... Purchasing amachine in the crate orwithout proper dealer set--up will void your warranty coverage...

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HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service, you must take it to a Polaris dealer autho- rized to repair Polaris ATVs... When requesting warranty service you must present your copy of theWarrantyRegistration form to the dealer... (THECOSTOFTRANS- PORTATIONTOANDFROMTHEDEALER ISYOURRESPONSIBILITY)... Polaris suggests that you use your original selling dealer; however, you may use any Po- laris Servicing Dealer to perform warranty service... Please work with your dealer to resolve any warranty issues... Should your dealer require any additional assistance they will contact the appropriate person at Polar- is... This warranty gives you specific legal rights, and you may also have other rights which vary from state to state... If any of the above terms are void because of state or federal law, all otherwarranty terms will remain in effect... Engine Oil 1... Always use Polaris engine oil... 2... Never substitute ormix oil brands as serious engine damage and voiding ofwar- ranty can result...

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Engine Cooling System 45-46... ... ... ... ... ... ... ... ... ... Air Cleaner 92-95... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Air Filters 93-95... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... All Wheel Drive 43... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Backing Up 71... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Battery Installation 74... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Battery Maintenance 73... ... ... ... ... ... ... ... ... ... ... ... ... ... Battery Removal 74... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Brake, Auxiliary 41 and 98... ... ... ... ... ... ... ... ... ... ... ... ... Brake, Front 97... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Brake, Parking 40... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Brake, Rear 98... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Brakes, Front 39... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Brakes, Rear 39... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Break In Period 57... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Break In Period -- 4 Cycle 56-57... ... ... ... ... ... ... ... Breather Filter 95... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Camber and Caster 96... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Carburetor Adjustment (4 Cycle) 103... ... ... Carburetor Adjustment (2 Cycle) 102... ... ... Carburetor Adjustments 121... ... ... ... ... ... ... ... ... ... ... Cargo Weight Distribution 60... ... ... ... ... ... ... ... ... ... Carrying Loads 59... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Chain Adjustment 112... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Choke Adjustment (4 Cycle) 102... ... ... ... ... ... ... Choke Adjustment Procedure 101... ... ... ... ... ... Choke Lever 38... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Cleaning Your ATV 120... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Control and Parts Functions 35-54... ... ... ... ... ... Coolant Level 45... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Coolant Level Inspection 46... ... ... ... ... ... ... ... ... ... ... Counter Balance Lubrication 108... ... ... ... ... ... ... Counter Balance Oil Changing

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