Polaris 2002 ATV Universal Owner's Manual PDF

Pages 181
Year 2002
Language(s)
English en
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1 of 181

Summary of Content for Polaris 2002 ATV Universal Owner's Manual PDF

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

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WELCOME Thank you for choosing Polaris, 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 recreational vehicles manufactured in the world today... Many years of experience in engineering, design, and development have gone into making your Polaris vehicle the finest machine weve ever produced... Follow the instructions and recommendations in this Owners Manual for safe and enjoyable operation of your vehicle... Your Owners Manual contains instructions for minor maintenance... Major repairs are covered in the Polaris Service Manual and should be performed by a Factory Certified MSD (Master Service Dealer) Technician... Your Polaris 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 on our online store 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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SAFETY TRAINING When you purchased this vehicle your dealer offered a hands-on safety training course covering all aspects of ATV safety... In addition, you were provided with certain printed material which instructs you on safe operating procedures... You should review this information on a regular basis... In the event you purchased a used Polaris ATV from a party other than a Polaris dealer, you can obtain this safety training at no charge from any authorized Polaris dealer... Failure to follow the warnings contained in this manual can result in SEVERE INJURY OR DEATH... NOTE: Illustrations used in this manual are for general representation only... Your model may differ...

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TABLE OF CONTENTS Vehicle Identification Numbers 6... ... ... ... ... ... ... ... ... ... ... ... ... ... Safety 7 - 42... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...

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Trouble Shooting 169 - 172... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Warranty 173 - 175... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...

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

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

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SAFETY Key Safety Issues Protect Your Sport Know all local, state/province riding laws; Respect your vehicle; Respect the environment; and You will gain the respect of others... We also advise you to strictly follow the recommended maintenance program as outlined... This preventive maintenance program is designed to ensure that all critical components on this ATV are thoroughly inspected at various intervals... All information in this manual is based upon the latest product data and specifications available at the time of printing... Polaris Industries Inc... reserves the right to make product changes and improvements which may affect illustrations or explanations... No part of this manual shall be reproduced or used without the written permission of Polaris Industries Inc... Illustrations included in this manual are general representations of parts having a similar function... Your model may differ... AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE... An ATV handles differently from other vehicles including motorcycles and cars... A collision or rollover can occur quickly, even during routine maneuvers such as turning and driving on hills or over obstacles, if you fail to take proper precautions...

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S Never operate an ATV without wearing an approved helmet that fits properly... You should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket, and long pants...

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S 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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FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety Commission at 1-800-638-2772, or Polaris at 1-800-342-3764... Additional Important Information... Due to our concern for the safety of our customers and the general public, Polaris hereby strongly recommends and requests that consumers not have installed on a Polaris ATV any equipment which is intended to increase the speed or power of the vehicle; or make any other modifications 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 these modifications may create a substantial safety hazard... Polaris hereby informs you that the warranty on your ATV is terminated if any such equipment has been added to the ATV or any modifications have been made to the ATV which increase its speed or power... We also advise you to strictly follow the recommended maintenance program outlined in this manual... This preventive maintenance program is designed to ensure that all critical components on the ATV are thoroughly inspected by your dealer at various mileage intervals...

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SAFETY Safety Decals and Locations NOTE: Warning decals have been placed on the vehicle for your protection... Read and follow the instructions on each decal carefully... In the event any decal becomes illegible or comes off, contact your Polaris dealer for a replacement... Any safety decal needing replacement will be provided by Polaris at no charge... The part number is printed on the decal...

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IF OWNERS MANUAL IS MISSING, CONTACT YOUR POLARIS DEALER FOR A REPLACEMENT...

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F Never operate this ATV on HILLS steeper than 25 degrees To prevent flipover on hilly terrain, when going up or down, use throttle and brakes gradually...

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

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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 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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WARNING Pushing reverse override button may cause sudden in- creases in pow- er and traction if too much throttle is ap- plied... Loss of control or for- ward flipover may result, es- pecially in AWD... See Own- ers Manual...

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1... Helmet Your helmet is the most important piece of protective gear for safe riding... A helmet can prevent a severe head injury... Select an approved helmet which meets or exceeds your states safety standards and bears either the Department of Transportation (DOT) label, the American National Standards Institute label (ANSI z90... 1), or the Snell Memorial Foundation label...

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POTENTIAL HAZARD Operating this ATV without proper instruction... WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain... HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Polaris Industries Inc... They should then regularly practice the skills learned in the course and the operating techniques described in the Owners Manual... For more information about the training course, contact an authorized ATV dealer or call Polaris at 1-800-342-3764...

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POTENTIAL HAZARD Carrying a passenger on this ATV... WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV... Could cause an accident, resulting in harm to you and/or your passenger... HOW TO AVOID THE HAZARD Never carry a passenger... The long seat is to allow the operator to shift position as needed during operation... It is not for carrying passengers...

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POTENTIAL HAZARD Operating this ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways... WHAT CAN HAPPEN The ATV tires are designed for off-road use... Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of control... HOW TO AVOID THE HAZARD

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POTENTIAL HAZARD Operating this ATV on public streets, roads or highways... WHAT CAN HAPPEN You can collide with another vehicle... HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one... In many states it is illegal to operate ATVs on public streets, roads and highways...

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POTENTIAL HAZARD Operating this ATV without wearing an approved helmet, eye protection and protective clothing... WHAT CAN HAPPEN Operating without an approved helmet increases your chances of a severe head injury or death in the event of an accident... Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident... HOW TO AVOID THE HAZARD Always wear an approved helmet which fits properly... You should also wear: eye protection (goggles or face shield); gloves; boots; long-sleeved shirt or jacket; and long pants...

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POTENTIAL HAZARD Operating this ATV at excessive speeds... WHAT CAN HAPPEN Increases your chances of losing control of the ATV, which can result in an accident... HOW TO AVOID THE HAZARD Always travel at a speed which is proper for the terrain, visibility and operating conditions; and your experience...

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POTENTIAL HAZARD Attempting wheelies, jumps and other stunts... WHAT CAN HAPPEN Increases the chance of an accident, including an overturn... HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps... Dont try to show off...

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POTENTIAL HAZARD Removing hands from handlebars or feet from footrests during operation... WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off the ATV... If you remove a foot from the footrest, your foot or leg may come into contact with the rear wheels, which could injure you or cause an accident... HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of your ATV during operation...

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POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain... WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react... Could result in the ATV overturning or going out of control... HOW TO AVOID THE HAZARD

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POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain... WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn... HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain... Always be especially cautious on these kinds of terrain...

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POTENTIAL HAZARD Turning improperly... WHAT CAN HAPPEN ATV could go out of control, causing a collision or overturn... HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the Owners Manual... See page 78 ... Practice turning at low speeds before attempting to turn at faster speeds... Do not turn at excessive speed...

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POTENTIAL HAZARD Climbing hills improperly... WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn... HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the Owners Manual... See pages 80 through 83... Always check the terrain carefully before you start up any hill...

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POTENTIAL HAZARD Going down a hill improperly... WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn... HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in the Owners Manual... See page 82... NOTE: A special technique is required when braking as you go downhill...

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POTENTIAL HAZARD Improperly crossing hills or turning on hills... WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn... HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owners Manual on level ground... See page 83... Be very careful when turning on any hill... Avoid crossing the side of a steep hill if possible... When crossing the side of a hill: Always follow proper procedures as described in the Owners Manual... Avoid hills with excessively slippery or loose surfaces... Shift your weight to the uphill side of the ATV...

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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 83...

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POTENTIAL HAZARD Improperly operating over obstacles... WHAT CAN HAPPEN Could cause loss of control or a collision... Could cause the ATV 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 described in the Owners Manual...

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POTENTIAL HAZARD Operating this ATV through deep or fast flowing water... WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident... HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast flowing water... If you cannot avoid water which exceeds the recommended maximum depth (pg 84), go slowly, balance your weight carefully avoiding sudden movements, maintain a slow and steady forward motion, do not make sudden turns or stops, and do not make sudden throttle changes... 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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POTENTIAL HAZARD Operating this ATV with improper modifications... WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident... HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories... All parts and accessories added to this vehicle should be genuine Polaris Industries Inc... or equivalent components designed for use on this ATV; and should be installed and used according to instructions... If you have questions, consult an authorized Polaris ATV dealer...

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POTENTIAL HAZARD Riding on frozen lakes and rivers... WHAT CAN HAPPEN Severe injury or death can result if the ATV and/or the operator break through the ice... HOW TO AVOID THE HAZARD Never ride your ATV on a frozen body of water before you are sure the ice is thick enough and sound enough to support the machine and its operator, as well as the force that is created by a moving vehicle...

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POTENTIAL HAZARD Improperly operating over obstacles... WHAT CAN HAPPEN Could cause loss of control or a collision... Could cause the ATV 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 described in the Owners Manual...

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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 severe injury or death...

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3... 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...

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Do not start or operate an ATV with sticking or improperly operating throttle controls... A stuck or improperly operating throttle could cause an accident resulting in severe injury or death... Always contact your dealer for service repairs whenever throttle problems arise... Failure to check or maintain proper operation of the throttle system can result in the throttle lever sticking during riding and cause an accident... Always check the lever for free movement and return before starting the engine and occasionally during riding...

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Controls Brakes The front and rear brakes are applied by squeezing the left side brake lever toward the handlebar... The front and rear brakes are hydraulically activated disc type brakes which are activated by one lever only... Always test brake lever travel and reservoir fluid level before riding... When squeezed, the lever should feel firm... Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before riding... Contact your dealer for proper diagnosis and repairs...

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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 an indicator window (1) on the top of the master cylinder... This eye will appear dark when the fluid level is full... When fluid needs to be added, the eye will be clear... NOTE: When checking the fluid level, the ATV must be on level ground the the handlebars straight... If the fluid level is low add DOT 3 (PN 2870990) only...

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

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Your Polaris ATV has an auxiliary brake (1) provided as a safety feature... It is located on the inside of the right floor board and is operated by the right foot... It is intended as a backup to the main brake system, especially if the main system becomes inoperative... If the rear wheels slide, reduce brake pedal pressure to brake the rear wheels without skidding... Aggressively applying the rear brake when backing down a hill may cause rear tip over... Brake Fluid Level It will be necessary to check the brake fluid level for the auxiliary brake system... The reservoir is located under the seat or near the foot brake... The fluid should be kept between the maximum and minimum marks...

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Fuel System The fuel tank filler cap (1) is located directly behind the handlebar... Refer to your owners Manual Supplement for tank capacity... Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R+ M/2 octane... The fuel valve is located on the left side of the front fender and has three positions: OFF: For vehicle storage and whenever transporting... ON: For normal operation... RES: For reserve supply in the event of main supply exhaustion... NOTE: There is about a 7 to 10 mile (11... 2 to 16 km) range on reserve gas... Always refill the gas tank as soon as possible after having used the reserve supply... Always return valve to on position after refueling machine...

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

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On models with a two cycle engine, the engine oil injection tank filler cap (2) is located on the front of the machine... Refer to your Owners Manual Supplement to determine the type of engine your vehicle has... The tank capacity is 2 quarts (1... 9 l)...

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CONTROLS AND FEATURES Controls Automatic Transmission Gear Selector Shift patterns depend on the type of vehicle you own... Please check your Owners Manual Supplement to define your machines shift pattern... The transmission gear selector is located on the right side of the vehicle directly above and forward of the engine recoil starter... The transmission selector lever has three or four positions: high forward; reverse; neutral; and low forward or forward; reverse; and neutral... Check your Owners Manual Supplement for specification... NOTE: To extend belt life, use low forward gear in heavy pulling situations and in situations where you are operating below 7 miles per hour for extended periods of time...

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Controls Manual Shift The engine can only be started with the transmission in neutral... Turn the key to on and ensure the stop switch is in the run position... The neutral indicator light should be on... If it is not, shift the foot pedal down ( or up and down, if in Reverse) to find neutral... Refer to the gear shift pedal illustrated on this page... Once the vehicle is in neutral, start the engine by engaging the starter...

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CONTROLS AND FEATURES Controls Shift Pedal The gear shift pedal is above the left floorboard... One full stroke of the pedal shifts the transmission to the next higher or lower gear in the shifting sequence... The pedal automatically returns to the horizontal position when released... The Xpedition has five forward gears (1, 2, 3, 4, and 5)... To upshift to a higher gear, put the toe of your boot under the gear shift pedal and raise the pedal one full stroke... To downshift, step on the gear shift pedal and depress the pedal one full stroke...

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Controls Shifting to Reverse With the ATV running and in neutral, hold the brake lever and push the Reverse/Override button on the LH control... Depress the gear shift pedal one stroke... The reverse indicator light will come on... Slowly release the brake lever and press throttle control lightly...

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To Decelerate When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly... As you slow down, shift to a lower gear... Be certain the engine has sufficiently slowed before engaging a lower gear... Improper use of the brakes or shifting can cause the tires to lose traction, reducing control and increasing the possibility of an accident...

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If the battery is weak and cannot start the engine, use of the recoil starter (A) 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... This makes recoil starting possible by allowing compression to leak at cranking speeds... The decompressor senses when the engine is spinning fast enough to start and restores compression for starting...

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CONTROLS AND FEATURES Features Exclusive AWD System (All Wheel Drive) Polaris 4 wheel drive ATVs are equipped with a unique, Polaris exclusive, Demand 4 Drive (AWD) system which is activated by a switch (1) on the right handlebar... When the switch is off the ATV is in 2 wheel drive at all times... When the switch is on the ATV is in Demand 4 Drive and the AWD indicator(2) will light... When in AWD, the front wheels will automatically engage anytime the rear wheels lose traction... When the rear wheels regain traction, the front wheels will automatically disengage... NOTE: The override switch also allows activation of Demand 4 Drive (AWD) in reverse, if Demand 4 Drive switch is on... There is no limit to the length of time the vehicle may remain in Demand 4 Drive... The Demand 4 Drive switch may be turned on or off while the vehicle is moving... If the switch is turned off when the front hubs are driving they will not release until the rear wheels regain traction... NOTE: Select AWD models do not have an AWD switch... These models are continuously in All Wheel Drive...

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Disengaging Wheel Hubs When backing up while in Demand 4 Drive and then going forward, one or both hubs may remain engaged... If one or both hubs remain engaged they can be disengaged by stopping, shifting to and moving in reverse... Then proceed in forward again... You can tell if only one front hub is engaged if the handlebars pull to one side... If both front wheel hubs are engaged, steering effort increases but remains balanced from left to right, and vehicle speed is somewhat restricted...

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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 information in your Owners Manual Supplement and in the information on this page will help you identify the lights on your machine and their function... 1 Transmission Neutral (Green) 2 Transmission Reverse (Yellow) 3 Oil Warning (Red) On 2 cycle models, this light indicates a low oil level... 4 High Temp (Red) (Will light only if engine overheats) 5 All Wheel Drive (Red) (located on the throttle control) Refer to page 58... 6 High Beam Indicator (Blue) (located on the LH switch on models equipped with Hi-Lo beam lights) With engine running, verify function of indicator lights each time ATV is used... NOTE: The taillight is on whenever the main switch (key) is in the on position... Turn the key off to prevent battery drain...

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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 measures distance in miles and kilometers as well as hours of operation... The speedometer also includes a reverse speed limit function that limits the ATVs speed in at approximately 7 to 9 mph... Refer to page 43 for additional information... 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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Accessing Sub-menu Features There are two methods for accessing the sub menu: 1... Press and hold the button and turn the power on 2... Press and hold the button for 8 seconds Hold the button until the display shows POLArS then release the button... The speedometer is now in the sub-menu... To display each mode, press the button once to scroll through the four available functions... Each function will be displayed as follows:

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TO CHECK WHEN SERVICE IS DUE BY HOURS Using the 50--hour service setting example from above, the speedometer will take the 50--hour setting and add it to the value of the hour--meter... This will be the value displayed when the operator checks when service is due for the ATV... For example, the hour meter reading is 132 hours, and the service interval was set for 50 hours, the 5--digit display will show 182 hours... 1... Access the sub--menu 2... Toggle to SET hr , then release the button 3... In 3 seconds, the LCD will display 5 digits, with the left--most

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To Clear The Service Reminder From The Display The reminder will remain in the LCD window until the button is pushed or it is reprogrammed for the next service interval... When this is done the display will return to the normal menu showing odometer, trip meter and hour meter... If the service interval isnt reprogrammed the reminder will be displayed each time the speedometer is powered up; again pushing the button can clear the display...

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Auxiliary Power Outlet Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights... On select models, an outlet is located on the front headlight pod... To determine if your vehicle is equipped with auxiliary power outlet, please check your Owners Manual Supplement... Accessory outlets are available for all models... Contact your Polaris dealer for more information...

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that axle nuts are secured by cotter pins 8... Drive chain - condition and slack; refer to drive chain adjustment 9... Air cleaner element - check for dirt; clean or replace 10... Steering - check for free operation noting any unusual looseness in

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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 performance and longer life for the engine... Perform the following procedures carefully...

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

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Break-In Period 4-Cycle Engines The break in period for your new Polaris ATV is defined as the first ten hours of operation, or the time it takes to use the first two 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...

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NOTE: the choke is on FULL when the knob is pulled out all the way... The choke is OFF when the knob is pushed in... This is a variable choke and can be adjusted gradually, depending on how much choke is needed for starting... 7... Do not press the throttle while starting the engine... 8... Activate the starter for a maximum of five seconds, releasing the

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Cold Weather Operation - 4 Cycle Engines Polaris offers the following kits for cold weather operation: Oil Tank Cover, Engine Heater and Oil Tank Heater... These kits reduce moisture accumulation in the oil tank when the ATV is operated in freezing temperatures... If you use your ATV all year round, it is important to check your oil level frequently... A rising oil level could indicate the accumulation of water in the bottom of the oil tank... Water in the bottom of the tank can lead to engine damage and must be drained... Water accumulation increases as outside temperature decreases... The cold weather kits not only reduce moisture accumulation, but the heaters provide quicker warm-ups and easier starting... See your dealer for more information on cold weather operation and what kit will work best for your driving habits...

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OPERATION Carrying Loads Your ATV has been designed to carry a certain amount of load... CARGO WEIGHT should be evenly distributed (1/3 on the front and 2/3 on the rear) and mounted as low as possible... When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions... Never exceed the weights specified in your Owners Manual Supplement... Maximum trailer weight - 850 lbs... (386 kg); maximum vertical hitch weight - 30 lbs... (14 kg)... Select models may tow up to 1225 (556 kg) on level ground only with a maximum vertical hitch weight of 35 lbs... (16 kg)... Refer to your Owners Manual Supplement to determine your machines capabilities... Know your machine before your ride... Maximum grade while trailer towing - 15... Do not tow any trailer on a grade steeper than 15... If your machine is equipped with a front rack, take care when loading... Improper loading of the front rack can obstruct the headlight beam, reducing night visibility... Do not obstruct the headlight beam with cargo... Use of low forward gear is recommended in heavy pulling situations to extend belt life...

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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 affects the vehicles turning, stopping distance and stability... Failure to follow loading requirements could cause severe injury or death...

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S DO NOT TRAVEL FASTER THAN THE REC- OMMENDED SPEEDS... Vehicle should never exceed 10 mph (16 kph) while towing a load on a level grass surface... Vehicle speed should never exceed 5 mph (8 kph) when tow- ing loads in rough terrain, while cornering, or while ascend- ing or descending a hill...

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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 to 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... ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW INCLUDE BUT ARE NOT LIMITED TO THE FOLLOWING: 1... Removal or alteration or the puncturing of the muffler or any engine

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axle nuts are secured by cotter pins 8... Drive chain - condition and slack; refer to drive chain adjustment 9... Air cleaner element - check for dirt; clean or replace 10... Steering - check for free operation noting any unusual looseness in

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3... Check your surroundings and determine your path of travel... 4... Release the parking brake... 5... Slowly depress the throttle with your right thumb and begin driving...

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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... This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly... To 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...

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Whenever riding on slippery surfaces such as wet trails or loose gravel, or during cold freezing weather, special atten- tion 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

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Whenever traveling uphill always travel straight uphill and: 1... Avoid steep hills (25_ maximum)... 2... Keep both feet on the footrests... 3... Transfer your weight forward... 4... Proceed at a steady rate of speed and throttle opening... 5... Remain alert and be prepared to take emergency action... This may

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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... 2... Lean into the hill transferring your upper body weight toward the hill

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Whenever descending a hill, always: 1... Drive directly downhill... 2... Transfer your weight to the rear of the vehicle... 3... Slow down... 4... Apply the brakes slightly to aid in slowing... Familiarize yourself with the auxiliary rear brake pedal and its use in the event loss of normal service brakes occurs...

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If the ATV stalls while climbing a hill, never back it down the hill! 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

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Your Polaris ATV can operate through water up to maximum recommended depths reaching the footrests... Before fording streams always: 1... Determine water depths and current... 2... Choose a crossing where both banks have gradual inclines... 3... Proceed slowly, avoiding rocks and obstacles if possible... 4... After crossing, dry the brakes by applying light pressure to the

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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 low hanging branches...

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control may result... NOTE: Most Polaris ATVs are equipped with a reverse speed limiter... The override button should be used with caution as rearward vehicle speed is greatly increased... Do not operate at wide open throttle... Only open the throttle enough to maintain a desired speed... Manual shift models (Xpedition) do not have a reverse speed limiter or an override...

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Whenever the Vehicle is Parked 1... Turn the engine off... 2... Place the transmission in gear or in park... 3... Set the parking brake... 4... Avoid parking on an incline... If it is necessary to park on an

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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 chart on the following pages... Maintenance intervals are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour... Vehicles subjected to severe use, such as operation in wet or dusty areas, should be inspected and serviced more frequently... If you are not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations... Inspect, clean, lubricate, adjust or replace parts as necessary... NOTE: Inspection may reveal the need for replacement parts... Always use genuine Polaris parts available from your Polaris dealer... Service and adjustments are critical... If you are not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations...

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Headlamp Inspection Pre-ride Pre-ride Check operation daily; ap- ply Polaris dielectric grease to connector when replaced

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" More often under severe use, such as dirty or wet conditions to purge water or dirt contamination from grease fittings and other critical components... L Emission Control System Service (California - 4-Cycle) NOTE: Some 4-Cycle models may have an additional California -only emissions warranty... Please refer to your owners manual supplement to determine if this applies to your vehicle...

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Inspect-adjust, lubricate, replace if necessary; pre- ride inspection item

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" More often under severe use, such as dirty or wet conditions to purge water or dirt contamination from grease fittings and other critical components... L Emission Control System Service (California - 4-Cycle) NOTE: Some 4-Cycle models may have an additional California -only emissions warranty... Please refer to your owners manual supplement to determine if this applies to your vehicle...

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Periodic inspection, adjust when parts are replaced

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Remove set screw in hubs... Rotate wheels to 4 Oclock position... If lubri- cant is not visible add more... Reinstall set screw...

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MAINTENANCE AND LUBRICATION Lubrication Recommendations

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MAINTENANCE AND LUBRICATION Lubrication Recommendations 10... Front Drive Axle (U Joint) (AWD Models)

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MAINTENANCE AND LUBRICATION Lubrication Recommendations

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L 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 before long periods of storage or after pressure washing, or after submerging in water... Always use Polaris Premium U-Joint Lube for maximum service of these driveline components (PN 2871515 3 oz... )(PN 2871551 14 oz... )... When suspension action becomes stiff or after washing... NOTE: Hours are based on 10 mph average...

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MAINTENANCE AND LUBRICATION Lubrication Recommendations

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

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Coolant Level The recovery bottle(1), located on the left side of the machine, must be maintained between the minimum and maximum levels indicated on the recovery bottle... The engine coolant level is controlled or maintained by the recovery system... The recovery system components are the recovery bottle, radiator filler neck, radiator pressure cap and connecting hose... As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator past the pressure cap and into the recovery bottle... As engine coolant temperature decreases the contracting (cooled) coolant is drawn back up from the tank past the pressure cap and into the radiator... NOTE: Some coolant level drop on new machines is normal as the system is purging itself of trapped air... Observe coolant levels and maintain as recommended by adding coolant to the recovery bottle... Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water... NOTE: Polaris Premium 60/40 is already premixed and ready to use... Do not dilute with water... NOTE: Always follow the manufacturers mixing recommendations for the freeze protection required in your area... To access the recovery bottle on Gen IV machines (B) it is necessary to remove the left side panel as described on page 164...

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Radiator Coolant Level Inspection NOTE: This procedure is only required if the cooling system has been drained for maintenance and/or repair... However, if the recovery bottle has run dry, the level in the radiator should be inspected and coolant added if necessary... To access the radiator pressure cap: Gen III (A) - To access the pressure cap, clean the area around the oil cap and remove the oil cap (2-cycle models)... Remove front cover by placing your fingers under the front of the cover and pulling upward... Reinstall oil cap... Gen IV (B) - Using the tool provided, remove the four screws securing front rack (2)... Remove front cover (3) by placing your fingers under the front of the cover and pulling upward...

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Engine Cooling System 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... To insure that the coolant maintains its ability to protect the engine, it is recommended that the system be completely drained every two years and a fresh mixture of antifreeze and water 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 manufacturers mixing recommendations for the freeze protection required in your area... Using a funnel, slowly add coolant as necessary through the radiator filler neck...

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Polaris 2-Cycle Lubricants Polaris has a family of premium oils available for use in all our products and highly recommends their use... The only oils recommended for Polaris 2-cycle ATVs are Polaris Premium 2-cycle oil or Premium Gold Synthetic 2-cycle oil... Polaris Premium 2-cycle lubricants are the most advanced formulation of oils specifically 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 lubricants provide additives for 2-cycle engines lacking in todays fuel that keep ring grooves cleaner for less ring sticking and provide improved overall engine cleanliness... With new generation lubricity technology, they excel in meeting the lubrication demands of 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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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 in more efficient operation, more power output, lower fuel consumption, and easier starting in cold temperatures... 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 more frequently if Polaris Premium 4 is not used... You will also need to follow the manufacturers recommendations for ambient temperature operation...

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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 travel before throttle slide starts to open... See Owners Manual Supplement...

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

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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, 200 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 when most trips are slow speed and less than 5 miles... Be sure to change the oil filter whenever changing oil

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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 to 25 in... lbs...

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13... Approximately 1 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...

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turn filter counterclockwise to remove... 9... Using a clean dry cloth, clean filter sealing surface on crankcase... 10... Lubricate O-ring on new filter with a film of engine oil... Check to

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NOTE: Drain Plug Torque: 14 ft... lbs... (19 Nm); Oil Filter Torque: Turn by hand until filter gasket contacts the sealing surface, then turn an additional 1/2 turn...

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turn filter counterclockwise to remove... 9... Using a clean dry cloth, clean filter sealing surface on crankcase... 10... Lubricate O-ring on new filter with a film of engine oil... Check to

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bring the level to the upper mark on the dipstick... 16... Dispose of used filter and oil properly... NOTE: Drain Plug Torque: 14 ft... lbs... (19 Nm); Oil Filter Torque: Turn by hand until filter gasket contacts the sealing surface, then turn an additional 1/2 turn...

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turn filter counterclockwise to remove... 9... Using a clean dry cloth, clean filter sealing surface on crankcase... 10... Lubricate O-ring on new filter with a film of engine oil... Check to

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bring the level to the upper mark on the dipstick... 16... Dispose of used filter and oil properly... NOTE: Drain Plug Torque: 14 ft... lbs... (19 Nm); Oil Filter Torque: Turn by hand until filter gasket contacts the sealing surface, then turn an additional 1/2 turn...

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Lubrication Transmission Lubrication - Models with Fill Plug Scrambler 500 4x4, Xplorer 400, Xplorer 4x4, Magnum 500, Magnum 325 4x4, Magnum 325 2x4 The transmission fill plug is located on the right side of the machine behind the propshaft shield or footwell... The transmission lubricant level should be checked every six months or 1000 miles (1600 km), whichever comes first... Transmission oil should be changed annually... With the ATV on a level surface, remove fill plug (1) and check the lubricant level... Use the illustration and the chart below to determine the correct fluid level... The correct transmission lubricant to use is Polaris Premium Synthetic Gearcase Lubricant (PN 2871478)...

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Lubricant until oil reaches the bottom of the filler hole... 6... Check for leaks... 7... Reinstall propshaft shield or footwell and screws removed in step

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For most 2x4 models, a transmission dipstick is located on the right side of the machine... On the Sportsman, the dipstick is located near the rear brake disc... 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 transmission oil drain plug area... 3... Loosen jam nut (A)... 4... Turn adjuster bolt (B) in to allow the removal of drain plug (C)... 5... Remove the drain plug and wipe the magnetic end clean to remove

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Lubrication Sportsman Transmission Oil Changing Procedure 1... Remove fill plug/dipstick... 2... Remove transmission drain plug side

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MAINTENANCE AND LUBRICATION Lubrication Front Gearcase Lubrication The front gearcase fill plug is located as shown... 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... Type A - 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... Type B - The lubricant level in this type of gearcase cannot be checked... You must periodically drain it and refill it according to the following procedure...

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Lubrication Rear Gearcase Lubrication With the ATV on a level surface, remove fill plug and visually inspect the lubricant level through the fill hole (1)... Lubricant should be kept even with the center of the drillpoint (2) approximately 1 5/8 below the top of the fill hole... NOTE: Do not add lubricant to the bottom of the fill plug threads... The correct gearcase lubricant to use is GL5 80-90 Weight Gear Lube...

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4... Starter Pinion Drain 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 before off season storage... 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 counter balance components... Always use SAE 10W30 oil...

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transmission fluid funnel until oil is at the proper level on the dipstick... If overfilled, excess oil will be expelled through the vent hose...

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

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Filter Removal and Service Procedure 1... Remove the ATV seat... 2... Unsnap the clips holding the cover assembly to the air box... 3... Loosen clamp securing the filter and remove the filter... 4... Remove the foam pre-filter from the main filter... 5... Wash pre-filter in soapy water, rinse and let dry... 6... Re-install pre-filter over main filter... Replace main filter if

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MAINTENANCE AND LUBRICATION Filter Systems Cleaning the Main Filter NOTE: 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

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4... Reinstall filter and clamps with arrow pointing toward engine... * Refer to your owners manual supplement to determine if your machine has a dry sump...

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Toe Alignment You can check the toe alignment of the vehicle using the following method... The recommended 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

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Adjustments Toe Alignment (cont... ) 2... Place stands in front of the machine, perpendicular to the rear tires... 3... Tie an elastic string around the stands, making sure string just

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MAINTENANCE AND LUBRICATION Adjustments Rear Spring Adjustment The rear shock absorber spring is adjusted by rotating the adjuster in the direction required to increase or decrease spring tension... NOTE: Accessory springs are available through your Polaris dealer...

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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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The front brakes are hydraulic disc brakes which are activated by the brake lever being moved toward the handlebar... These brakes are self-adjusting and require no adjustment... The following checks are recommended to keep the brake system in good operating condition... How often they need checking depends upon the type of driving that has been done... S Keep fluid level in the master cylinder reservoirs as described on

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wear... Auxiliary Brake Systems Your ATVs auxiliary brake system is intended to be used as a backup for the main brake system... Should the main system fail, the rear brake can be activated by depressing the foot pedal on the inside of the right floorboard... All Polaris ATVs have hydraulic brake systems... The hydraulic auxiliary brake system will not require adjustment... NOTE: Since this is a rear brake only, it will not be as effective as the all wheel system...

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MAINTENANCE AND LUBRICATION Adjustments 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

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Adjustments Carburetor/Engine Idle RPM Adjustment 4-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

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MAINTENANCE AND LUBRICATION Adjustments Cylinder Head/Cylinder Base Fastener Torque (2-Cycle Models) Have your dealer check the ATV cylinder head and cylinder base fasteners for proper torque at the first service or after 25 hours...

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Important Safeguards Maintain proper tire pressure according to charts below... Improper tire inflation may affect ATV maneuverability... Do not use improper tires... The use of non-standard size or type tires may affect ATV handling... Make certain the wheel are installed properly... If wheels are improperly installed it could affect vehicle handling and tire wear...

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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...

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

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Always inspect the drive chain prior to operating the vehicle, checking for damaged or missing O-rings, rollers and correct slack adjustment... Maintain the stone guard to rear sprocket clearance at 1/8 (... 3 cm)... Regularly lubricate the drive chain with SAE 80-90 lube or an approved O-ring chain spray lube...

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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 have 3/16-3/8 (... 48 cm - ... 95 cm) deflection (1)... If the chain needs adjustment, use the following procedure...

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7... Tighten caliper mount bolts 10-12 ft... lbs... (1... 4 - 1... 7 kg/m) 8... Remove pin punch... 9... Roll ATV foward checking chain tension in several places around

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Adjustments Carburetor Adjustments If the vehicle is to be operated at various altitudes and temperatures, certain adjustments can be made to improve its operation and driveability... Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich... An engine loses approximately 3% of its power for each 1000 foot (304... 8 m) increase in elevation... 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

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Headlight Lamp Replacement - Scrambler 1... Remove wire harness connector from the back of headlight... 2... Grasp bulb housing, turn counterclockwise and remove bulb... 3... Install bulb into headlight housing and rotate clockwise firmly...

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and make a mark on the wall at the same height... 3... Start the engine and turn the headlight switch to high beam... 4... Observe headlight aim... The most intense part of the headlight

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5... Adjust beam to desired position by turning adjustment screws (1) 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... Unplug headlamp from wiring harness... 6... Remove boot and locking collar from back of lamp housing... 7... Grasp base of lamp and lift it out... 8... Reverse previous steps to replace lamp and reassemble pod... Make

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MAINTENANCE AND LUBRICATION Lights -- Adjustment -- Replacement High Beam Headlight Adjustment (Gen IV) The headlight beam can be adjusted to any position desired by turning the adjusting knob located on the bottom right side of the headlight pod... 1... Place the vehicle on a level surface with the headlight

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through the two small openings at the front of the headlight pod... 2... Lift the pod lightly while depressing the tabs... 3... Remove the screw in the back

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MAINTENANCE AND LUBRICATION Lights -- Adjustment -- Replacement Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work the lamp may need to be replaced... 1... Remove the taillight lense

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1... Normal The insulator tip is gray, tan or light brown... There will be few combustion deposits... The electrodes are not burned or eroded... This indicates the proper type and heat range for the engine and the service... NOTE: The tip should not be white... A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetion adjustments...

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

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Spark Arrestor The exhaust pipe must be periodically purged of accumulated carbon as follows: 1... Remove the clean out plugs (1) located on the bottom of themuffler as

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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...

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Recoil Housing Drain the recoil housing after operating the ATV in very wet conditions... This should also be done before storing the ATV... The drain screw is located at the bottom of the recoil housing... Using a wrench, remove the screw... Reinstall screw once housing has been drained... Water will enter the recoil housing if the starter handle is disengaged from the rope guide when under water... After travelling in wet areas the recoil housing and starter should always be drained completely by removing the recoil... Do not open the crankcase drain unless the engine has ingested water... On 4-cycle engines, some engine oil will be lost if crankcase drain is opened... On the Trail Blazer, the recoil handle must be behind the heat shield for it to seal properly... If it is not sealed properly, water may enter the recoil housing and damage components... A - 250 and 400 Engines B - 4-Cycle Engines

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Low Range Use May Reduce PVT Operating Temperatures The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements... As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases... This, in turn, increases the amount of pinch applied to the drive belt... Similarly, if the engine speed decreases, the amount of centrifugal force decreases, reducing the amount of belt pinch...

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PVT System On Polaris ATVs, the approximate gear ratio difference between high and low range is 1:2... 25... This difference in gearing affects the operation of the PVT, especially at speeds less than 7 MPH, due to the systems dependence on engine speed... For example, when operating at a ground speed of 3 MPH in low range, the engine speed would be around 3000 RPM... This is well above the engagement speed of 1200 - 1400 RPM... However, in high range at 3 MPH, the engine would be running at only 1500 RPM... Whenever operating this close to the engagement speed, the engine may be running at a speed which is too low to provide adequate pinch needed to prevent belt slip... This belt slip is responsible for creating the excessive heat that destroys belts and causes outer clutch covers to fail... By switching to low range while operating at low ground speeds, the air temperature in the clutch cover is reduced by almost 160 degrees... Reducing the temperature inside the clutch cover extends the life of the PVT components (belt, cover, etc... )... NOTE;Models without a low range should avoid heavy pulling and extended low-speed operation...

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MAINTENANCE AND LUBRICATION PVT System When To Use Low Range vs... High Range The following lists provide a guideline for when to use low range rather than high...

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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...

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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 rags... Coat the terminals with dielectric grease or petroleum jelly... Be careful not to allow cleaning solution or tap water into the battery...

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S When installing a new battery, make certain it is fully charged prior to its initial use... Using a new battery that has not been fully charged can damage the battery resulting in a shorter life of the battery... It can also hinder vehicle performance...

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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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Washing 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 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 might have entered the engine or exhaust system... 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 washing mitten, 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 Polaris dealer for free replacement...

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Cleaning - Outside... Make necessary repairs and then clean the ATV thoroughly with a mild soap and warm water solution to remove all dirt and grime... Dont use harsh detergents or high pressure washers... Some detergents deteriorate rubber parts - use dish soap type cleaners only... High pressure washers may force water past seals... Drain the recoil housing... Stabilize Fuel - Fill the fuel tank... Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer... Follow instructions on the container for recommended amount... Carbon clean will also reduce the possibility of bacterial growth in the fuel system... Its best to allow 15-20 minutes of operation for the stabilizer to disperse through the fuel in the tank and carburetor... Turn the fuel valve to OFF and drain the carburetor bowl completely... Oil And Filter Change - (4-Strokes) Warm the engine and change oil and filter... Air Filter / Air Box - Inspect and clean or replace the pre-cleaner and air filter... Clean the air box and drain the sediment tube... Breather Filter(s) - On 4-Strokes, inspect and clean or replace the breather filter(s)... Inspect All Fluid Levels - Inspect the following fluid levels and change if necessary: engine counter balance (2-strokes); front gear case (shaft drive models); transmission; front hubs (AWD models); brake fluid (change every two years or as required if fluid looks dark or contaminated)... Drain Recoil Housing - Remove drain plug from recoil housing and drain any moisture present...

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Cleaning and Storage * Fog The Engine - 2 Strokes - Polaris Fogging Oil (PN 2870791) follow directions on the can... 4-Strokes - Remove the spark plug and add 2-3 tablespoons of Premium 4 Synthetic 0W40 engine oil... To access the plug hole use a section of clear 1/4 hose and a small plastic squeeze bottle filled with the pre-measured amount of oil... Note: Do this carefully! If you miss the plug hole, oil will drain from the spark plug cavity out the hole at the front of the cylinder head, and appear to be an oil leak... Install the spark plug and pull the engine over slowly with the recoil starter... Oil will be forced in and around the piston rings and ring lands, coating the cylinder with a protective film of fresh oil... Check and Lubricate Cables / Grease - Inspect all cables and lubricate with Polaris Cable Lubricant... Follow lubrication guidelines in the Maintenance Section of the Service or Owners Manual to completely grease and lubricate the entire vehicle with Polaris Premium All Season Grease... Apply Polaris O-ring Chain Lube to the drive chain(s)... Battery Maintenance - Remove the battery and add distilled water as required to the proper level... Do not use tap water which may contain minerals that reduce battery life... Apply Polaris Di-Electric Grease to the terminal bolts and terminals... Charge the battery at 1... 4 amps or less until specific gravity of each cell is 1... 265 or greater... Store the battery in a cool, dry, place... Charge can be maintained easily by using Polaris Battery Tendert charger (PN 2871076) or by charging about once a month to make up for normal self-discharge... Battery Tendert can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point... The only thing you need to do is check the fluid level once a month... Engine Anti-Freeze - Test engine coolant strength and change if necessary... Coolant should be replaced every 2 years... Storage Area/Covers - Set tire pressure and safely support the ATV with the tires 1-2 off the ground... Be sure the storage area is well ventilated... Cover the machine with a genuine Polaris ATV cover... NOTE: Do not use plastic or coated materials... They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation...

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MAINTENANCE AND LUBRICATION Cleaning and Storage * If you choose not to use Polaris fogging Oil, perform the following procedure... 1... Support the front end of the machine so the engine is level or tilted

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Stuck in mud or snow... Shift the transmission to Low Range, carefully use fast, aggressive throttle application to engage clutch... WARN- ING: Excessive throttle may cause loss of control and vehicle overturn...

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Shift the transmission to neutral... Using the throttle, vary the engine rpm from idle to full throttle... Re- peat several times as required... During this procedure, the throttle should not be held at the full posi- tion for more than 10 seconds... Clutch seals should be inspected for damage if repeated leaking oc- curs...

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

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Clean Radiator screen and Radiator Core (liquid cooled models)

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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 COMPLETE AN ATV SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE ATV... No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement... If you have not signed the original registration and received the customer copy, please contact your dealer immediately... NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS... Initial dealer preparation and set--up of your ATV is very important in ensuring trouble--free operation... Purchasing a machine in the crate or without proper dealer set--up will void your warranty coverage...

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LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship... This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling... This warranty also does not cover any ATV that has been altered structurally, modified, neglected, improperly maintained, used for racing, or used for purposes other than for which it was manufactured, or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts... In addition, this warranty does not cover physical damage to paint or finish, stress cracks, tearing or puncturing of upholstery material, corrosion, or defects in parts, components or the ATV due to fire, explosions or any other cause beyond Polaris control... This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with the ATV... The exclusive remedy for breach of this warranty shall be, at Polaris exclusive option, repair or replacement of any defective materials, or components or products... THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY... POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE... Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties, so the above limitations or exclusions may not apply to you if inconsistent with controlling state law...

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HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris ATVs... When requesting warranty service you must present your copy of the Warranty Registration form to the dealer... (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY)... Polaris suggests that you use your original selling dealer; however, you may use any Polaris 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 Polaris... 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 other warranty terms will remain in effect... Engine Oil 1... Always use Polaris engine oil... 2... Never substitute or mix oil brands as serious engine damage and voiding of warranty can result...

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Handlebar Adjustment 133... ... ... ... ... ... ... ... ... ... ... ... ... Headlight Adjustment 147-150... ... ... ... ... ... ... ... ... ... ... Headlight Lamp Replacement 146, 149... ... ... ... Indicator Lamp Replacement 152... ... ... ... ... ... ... ... Indicator Lights 60... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Key Safety Issues 8-11... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Light Switches 55... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Lights 146-152... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Lubricant, 2cycle 104... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Lubrication 104-126... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Lubrication Recommendations 94-99... ... ... ... ... ... Main Switch 43... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Maintenance and Lubrication 88-168... ... ... ... ... ... Maintenance Record 100... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Making Turns 78... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Manual Shift 53... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Noise Control System 75... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Oil Change 108-116... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Oil Change, Engine - 4 Strokes 111... ... ... ... ... ... ... ... Oil Filter Change 111... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Oil Pump Adjustment 106-107... ... ... ... ... ... ... ... ... ... ... Oil Pump Bleeding 108... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Oil System 49-51, 126... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Operation 66-74... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Operator Safety 22-42... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Override Switch 43... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Parking On An Incline 87... ... ... ... ... ... ... ... ... ... ... ... ... ... Periodic Maintenance Schedule 91-96... ... ... ... ... Pre Operation Inspection 76... ... ... ... ... ... ... ... ... ... ... ... Pre Ride Inspection 66... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Premium 4 Synthetic Lubricant 105... ... ... ... ... ... PVT System 158-160... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Rear Spring Adjustment 132... ... ... ... ... ... ... ... ... ... ... ... Recoil Housing 157, 166... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Recoil Starter 57... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Reverse 55... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Riding 76-87... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Riding On Slippery Surfaces 79... ... ... ... ... ... ... ... ... Safe Riding Gear 21... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Safety 8-42... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Safety Decals and Locations 12-20... ... ... ... ... ... ... ... Safety Warning and Operation Decals 13... ... Shift Pedal 54... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Shifting 54-56... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Side Panel Removal 164... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Sidehilling 81... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Spark Arrestor 155-156... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Spark Plugs 153... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Starting The Engine 70-71... ... ... ... ... ... ... ... ... ... ... ... ... ... Starting a Cold Engine 70... ... ... ... ... ... ... ... ... ... ... ... ... ... Steering Inspection 130... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Storage Tips 166... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Table Of Contents 4-5... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Taillight/Brakelight Lamp Replacement 152 Throttle Cable Adjustment 108... ... ... ... ... ... ... ... ... ... Throttle Lever 44... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Tire Inspection 141... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...

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Troubleshooting 169-172... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Turning Around On a Hill 83... ... ... ... ... ... ... ... ... ... ... ... Understanding Warnings 7... ... ... ... ... ... ... ... ... ... ... ... ... Vehicle Identification Numbers 6... ... ... ... ... ... ... ... Warranty 173-175... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Welcome 2... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Wheel Installation 139-140... ... ... ... ... ... ... ... ... ... ... ... ... ... Wheel Removal 139... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...

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