Polaris 2002 ATV Universal v2 Owner's Manual PDF

WARNING

The engine exhaust from this product contains chemicals

known to cause cancer, birth de- fects or other reproductive harm.

A card containing important safey information should be attached to the owners manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800-342-3764 for as- sistance.

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

WARNING

1

Weve created a web site, just for YOU!

S Technical tips

S New product introductions

S Event schedules

S Parts and Service Manual information

S Exciting details about The Way Out

Check it out...

www.polarisindustries.com/owner

2

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.

Copyright 2001 Polaris Industries Inc. All Rights Reserved Printed in the U.S.A.

3

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

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

SAFETY TRAINING When you purchased this vehicle your dealer 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.

4

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

Understanding Warnings 7. . . . . . . . . . . . . . . . . . . . . . . . .

Key Safety Issues 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Decals and Locations 12. . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Safety 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Features and Controls 43 - 65. . . . . . . . . . . . . . . . . Controls 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Features 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation 66 - 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pre Ride Inspection 66. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vehicle Break-In Period 67. . . . . . . . . . . . . . . . . . . . . . . . .

Starting the Engine 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Carrying Loads 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Noise Emission Control System 75. . . . . . . . . . . . Riding 76 - 87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pre Ride Inspection 76. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safe Riding Tips 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

TABLE OF CONTENTS

Maintenance and Lubrication 88 - 168. . . . . . . . . . Periodic Maintenance Schedule 88. . . . . . . . . . . . . . . . . .

Lubrication Recommendations 94. . . . . . . . . . . . . . . . . . .

Maintenance Record 100. . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling System 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication 104. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filter Systems 127. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustments 130. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lights 146. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spark Plugs 153. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water Service 154. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spark Arrestor 155. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recoil Housing 157. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PVT 158. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery 161. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Side Panel Removal 164. . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning and Storage 165. . . . . . . . . . . . . . . . . . . . . . . . . .

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

6

VEHICLE IDENTIFICATION NUMBERS

2

1

Record these numbers from your ATV in the spaces provided.

1. Frame VIN (found on the lower left side of the frame tube)

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

Remove the spare key and store in a safe place. Your key can be duplicated only by obtaining a key blank from Polaris and having it cut by mating it with your existing key.

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.

Dealer Imprint

7

SAFETY

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.

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

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

Indicates a potential hazard that may result in minor personal injury or damage to the machine.

WARNING

CAUTION

NOTE NOTE: will alert you to important information or instructions.

Indicates a situation that may result in damage to the machine.

CAUTION

8

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.

9

SAFETY

Key Safety Issues SERIOUS INJURY OR DEATH can result if you do not follow these instructions: S Read this manual and all labels carefully and follow the operating

procedures described. S Never operate an ATV without proper instruction. Take a training

course. Beginners should receive training from a certified instruc- tor. Contact an authorized Polaris ATV dealer or call Polaris at 1-800-342-3764 to find out about the training courses nearest you.

S Never allow anyone under 16 years of age to operate this ATV. S Never permit a guest to operate this ATV unless the guest has read

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

S Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets.

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

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.

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

S Never operate at excessive speeds. Always travel at a speed which is proper for the terrain, visibility and operating conditions, and your experience.

S Never attempt wheelies, jumps or other stunts. S Always inspect your ATV each time you use it to make sure it is in

safe operating condition. Always follow the inspection and main- tenance procedures and schedules described in this manual.

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

S Always go slowly and be extra careful when operating on unfamil- iar terrain. Always be alert to changing terrain conditions when operating the ATV.

S Never operate on excessively rough, slippery or loose terrain. S Always follow proper procedures for turning as described in this

manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed.

S Always have the ATV checked by an authorized Polaris dealer if it has been involved in an accident.

10

SAFETY Key Safety Issues S Never operate the ATV on hills too steep for the ATV or for your

abilities. Practice on smaller hills before attempting larger hills. S Always follow proper procedures for climbing hills as described in

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

S Always follow proper procedures for going down hills and for brak- ing on hills as described in this manual. Check the terrain careful- ly before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side. Go straight down the hill where possible.

S Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you have mastered the turning technique described in this manual on level ground. Avoid crossing the side of a steep hill if possible.

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.

S Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always follow proper procedures when operating over ob- stacles as described in this manual.

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

S Avoid operating the ATV through deep or fast flowing water. If you cannot avoid water which exceeds the recommended maxi- mum 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 sud- den throttle changes.

S Wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary apply them lightly several times to let friction dry out the pads.

11

SAFETY Key Safety Issues S Always be sure there are no obstacles or people behind you when

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

S Always use the size and type tires specified in this manual. Always maintain proper tire pressure as described in this manual.

S Never modify an ATV through improper installation or use of ac- cessories.

S Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and fol- low instructions in this manual for carrying cargo or pulling a trail- er. Allow greater distance for braking.

S Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting.

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

NOTE: The addition of certain accessories including (but not limited to) mowers, blades, tires, sprayers, or large racks may change the handling characteristics of the ATV. Be certain any accessories added to this ATV have been approved by Polaris. Familiarize yourself with their function and affect on the ATV.

12

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.

1

13

SAFETY

Safety Decals and Locations

1

7079083E1997, 2000

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

WARNING

14

SAFETY Safety Decals and Locations

2

3

15

SAFETY

Safety Decals and Locations

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.

25

F REVERSE operation can be dangerous even at low speeds. Steering becomes difficult. To prevent flipover, avoid sudden braking or sharp turns.

F Use OVERRIDE for reverse speed limiter with caution. To prevent loss of control, never activate override button with open throttle.

F PARKING BRAKE may relax when used for more than 5 minutes. When parking on grades, leave shift in forward.

7079085

Operating this ATV if you are under the age of 16 increases your chance of severe injury or death.

NEVER operate this ATV if you are under age 16.

7078253

UNDER

2

3

WARNING

WARNING

16

SAFETY Safety Decals and Locations

4

5

6

17

SAFETY

Safety Decals and Locations

4

5

(Refer to your Owners Manual Supplement for your vehicles specifications.)

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

TIRE PRESSURE (PSI): FRONT ___ REAR ___

MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING MACHINE, DRIVER AND CARGO IS ____ LBS.

Reduce speed and allow greater distance for braking when carrying cargo. Overloading or carrying tall, off-center, or unsecured loads will increase your risk of losing control. Loads should be centered, 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.

Read Owners Manual for more detailed loading information

(on rear of seat)

6

WARNING

18

SAFETY Safety Decals and Locations

7

8

ATTENTION D Operation of this

vehicle without the filter element will severely damage the engine.

D Clean air filter often, more frequent cleaning required in dusty conditions

(Under Seat)7

8

Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed.

Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM which can result in serious injury or death.

NO STEP 7078689

D Specific carburetor jetting and adjustments are required depending on temperature and altitude. See your Owners Manual.

Factory setting:

40_ to 80_ F. at 0-3000 feet (5_ to 27_ C. at 0-900 meters).

7079901

WARNING

19

SAFETY

Safety Decals and Locations

9 9

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.

Maximum Rack Loads: Front 90 lbs. Rear 180 Lbs 7070021

9

WARNING

20

SAFETY Safety Decals and Locations

ALL WHEEL DRIVE SWITCH

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

7079780

MANUFACTURED BY: POLARIS IND

DATE:

VIN:

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

PRINTED IN U.S.A. 7077185

CE VHICULE EST UN VHICULE TOUT TERRAIN QUI NiEST PAS DESTIN TRE UTILIS SUR LES CHEMINS PUBLICS.

TRAILER MAX. WEIGHT 850 LBS.

HITCH MAX. VERTICAL WEIGHT 30 LBS.

POIDS MAX. DE REMORQUE 386 KG.

POIDS MAX. VERTICAL DATTACHE 14 KG.

7079604

Reverse Speed is limited.

Reverse override is controlled by the override switch.

See your Owners Manual.

OVERRIDE SWITCH

7079906

AWD Models

2WD Models

7077542

TRAILER MAX WEIGHT: 1225 LBS. (556 KG) ON LEVEL GROUND 850 LBS. (368 KG) UP TO 15 GRADE

HITCH MAX. VERTICAL WEIGHT: 35 LBS. (16KG)

7072533

Chain Freeplay Is Important. Adjust Freeplay to 3/16 -- 3/8 DO NOT Overtension. See Owners Manual.

Torque Nut on Eccentric Bolts: To 30 Ft. Lbs.(For models without a hitch). To 60 Ft. Lbs. (For models with a hitch. 7078572

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.

NOTE: Your machine will not have all the decals depicted on this page. The decals found on your machine will depend on the model you own.

21

SAFETY

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

1. Helmet Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injury. Select an approved helmet 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.

2. Eye Protection Do not depend on sunglasses for proper eye protection. A pair of goggles or helmet 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).

3. Gloves Off-road style gloves with knuckle pads are the best for comfort and protection.

4. Boots The best footwear is a pair of strong over the calf type boots with heels, such as moto-cross boots.

5. Clothing To protect your body, long sleeves and pants should always be worn. Riding pants with kneepads, a jersey and shoulder pads provide the best protection.

1

2 3

4

5

22

SAFETY Operator Safety

POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain. HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Polaris 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.

POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child. Even though a child may be within the age group for which some ATVs are recommended, he or she may not have the skills, abilities, or judgment needed to operate the ATV safely and may be involved in a serious accident. HOW TO AVOID THE HAZARD No one under 16 should operate a Polaris ATV.

WARNING

WARNING

23

SAFETY

Operator Safety

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.

WARNING

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

WARNING

24

SAFETY Operator Safety

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

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

WARNING

25

SAFETY

Operator Safety

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.

WARNING

26

SAFETY Operator Safety

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.

WARNING

27

SAFETY

Operator Safety

POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident.

HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV.

POTENTIAL HAZARD Operating this ATV at excessive speeds. WHAT CAN HAPPEN 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.

WARNING

WARNING

28

SAFETY Operator Safety

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.

WARNING

29

SAFETY

Operator Safety

POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition.

Always follow the inspection and maintenance procedures and schedules described in the Owners Manual.

POTENTIAL HAZARD Removing hands from handlebars or feet from footrests during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off the ATV. If you remove a foot from the footrest, your foot or leg may come into 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.

WARNING

WARNING

30

SAFETY Operator Safety

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

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

WARNING

31

SAFETY

Operator Safety

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.

WARNING

32

SAFETY Operator Safety

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.

POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level surfaces or small hills. HOW TO AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for your abilities.

Practice on smaller hills before attempting large hills. Never operate ATV on hills steeper than 25_.

WARNING

WARNING

33

SAFETY

Operator Safety

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.

Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly. The ATV could flip over backwards. Never go over the top of any hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.

WARNING

34

SAFETY Operator Safety

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.

Always check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side. Go straight down the hill where possible.

WARNING

35

SAFETY

Operator Safety

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.

WARNING

36

SAFETY Operator Safety

POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN Could result in ATV overturning. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill. Apply the brakes. Lock parking brake after you are stopped. If you begin rolling backwards:

Keep weight uphill; never apply engine power. Never apply the rear brake while rolling backwards. Apply the single-lever brake gradually. When fully stopped, apply rear brake as well, and then lock 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.

WARNING

37

SAFETY

Operator Safety

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.

POTENTIAL HAZARD Skidding or sliding. WHAT CAN HAPPEN You may lose control of the ATV. You may also regain traction unexpectedly, which may cause the ATV to overturn. HOW TO AVOID THE HAZARD On slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.

WARNING

WARNING

38

SAFETY Operator Safety

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.

POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN You could hit an obstacle or person behind you, resulting in severe injury. HOW TO AVOID THE HAZARD When you select reverse gear, make sure there are no obstacles or people behind you. When it is safe to proceed, go slowly.

WARNING

WARNING

39

SAFETY

Operator Safety

POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of control, and increases the risk of an accident. HOW TO AVOID THE HAZARD

Always use the size and type tires specified in the Owners Manual Supplement for this vehicle. Always maintain proper tire pressure as described in the Owners Manual Supplement.

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.

WARNING

WARNING

40

SAFETY Operator Safety

POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV.

Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking. Always follow the instructions in the Owners Manual for carrying cargo or pulling a trailer. See pages 72 through 74.

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.

WARNING

WARNING

41

SAFETY

Operator Safety

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.

POTENTIAL HAZARD Skidding or sliding. WHAT CAN HAPPEN You may lose control of the ATV. You may also regain traction unexpectedly, which may cause the ATV to overturn. HOW TO AVOID THE HAZARD On slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.

WARNING

WARNING

42

SAFETY Operator Safety

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

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.

WARNING

WARNING

Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use.

WARNING

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

WARNING

CAUTION Keep combustible materials away from exhaust system. Fire may result.

43

CONTROLS AND FEATURES

Controls Engine Electrical Switches

1. Override Switch (Reverse Speed Limiter) - This vehicle is equipped with a reverse speed limiter system. To obtain additional power while backing up, depress the override button. 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 - To start the engine, slide the stop switch to the center run position and turn the main key switch clockwise past the on position. Release the key when the engine starts.

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.

1 2

3

WARNING Activating the override button while throttle is open can cause loss of control resulting in severe injury or death.

RUN OFFOFF

3

WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use.

44

CONTROLS AND FEATURES Controls Engine Throttle and Choke

Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle lever. The throttle lever (1) is spring loaded and engine speed returns to idle when the lever is released. This vehicle is equipped with a Polaris Electronic Throttle Control (ETC) which is designed to reduce the risk of a frozen or stuck throttle. In the event the throttle cable should stick in an open position, the engine will stop and power to the rear wheels will cease when the operator releases the throttle lever.

Choke Refer to the engine starting procedure on page 70 for correct choke and throttle settings during starting.

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.

WARNING

1

45

CONTROLS AND FEATURES

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.

Never operate the ATV with a spongy feeling brake lever. Operating the ATV with a spongy brake lever can result in loss of braking. Loss of braking could cause an accident.

WARNING

46

CONTROLS AND FEATURES Controls

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.

The Electronic Throttle Control (ETC) stops the engine in the event of a throttle system malfunction and is provided for your safety. Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms.

WARNING

1

Once a bottle of brake fluid is opened, use what is necessary and discard the rest. Do not store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. This causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of severe injury.

WARNING

47

CONTROLS AND FEATURES

Controls Parking Brake

Setting the Parking Brake 1. Squeeze the left hand brake

lever two or three times and hold it.

2. Push the park brake lock (2) into the notches on the master cylinder body. Release the brake lever.

3. To release the parking brake lock, squeeze the brake lever. It will return to its released position.

Important Safeguards S The parking brake may relax when left on for a long period of time.

This could cause an accident. S Do not leave the vehicle on a hill depending on the parking

brake for more than five minutes. S Always block the downhill side of the wheels if leaving the ATV

on a hill or park the ATV in a side hill position.

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.

WARNING

2

48

CONTROLS AND FEATURES Controls

Auxiliary Brake

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.

Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward or the rear wheels may skid and slide sideways causing loss of control.

WARNING

1

49

CONTROLS AND FEATURES

Controls Engine Fuel and Oil System

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.

Engine Fuel Safety/Fuel/Filter The Polaris ATV is equipped with an in-line fuel filter. This filter should be replaced by your dealer after every 100 hours of operation or annually. Do not attempt to clean the fuel filter.

1

ON

OFF

RES

50

CONTROLS AND FEATURES Controls Engine Fuel and Oil System

Gasoline is highly flammable and explosive under certain conditions.

S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped and outdoors or in a well

ventilated area. S Do not smoke or allow open flames or sparks in or near the

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

off with soap and water and change clothing. S Never start the engine or let it run in an enclosed area. Gaso-

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

S Shut off fuel valve whenever the ATV is stored or parked.

The engine exhaust from this product con- tains chemicals known to cause cancer, birth defects or other reproductive harm.

WARNING

WARNING

51

CONTROLS AND FEATURES

Controls Engine Fuel and Oil System

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).

On models with a two cycle engine, use only Polaris injection oil. Never substitute or mix oil brands. Serious engine damage and voiding of warranty can result. To avoid serious engine damage always top off the oil level when refueling.

CAUTION

2

52

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.

Always place the transmission in gear with the parking brake locked whenever the vehicle is left unattended. Maintaining shift linkage adjustment is important to assure proper transmission function. Should you experience any shifting problem see your dealer.

H

N

R

H L

N

R

H L

N

R P

To change gears, stop the vehicle and with the engine idling, move the lever to the desired gear. Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage.

CAUTION

53

CONTROLS AND FEATURES

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.

Brake Start

This model also has a brake start feature that can be used when it is difficult to find neutral. To activate, pull on the LH brake lever and engage the starter.

Gear Shift Pedal

1 2 34

5

12345

To shift to a higher gear, raise the pedal one full stroke.

To downshift, depress the pedal one full stroke.

N

N

R

R

54

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.

Shifting Gears Start the engine and let it warm up, follow this procedure: 1. With the transmission in neutral, hold the brake lever. 2. With the throttle closed, raise the gear shift pedal one full stroke to

shift into first gear. 3. Release the brake lever and increase engine speed by gradually

opening the throttle. 4. When speed increases, release the throttle and shift to 2nd gear by

raising the gear shift pedal one full stroke. 5. Repeat sequence 4. to progressively upshift to 3rd, 4th and 5th

(top) gear. 6. To downshift, reverse sequence 4. Remember to release the

throttle each time you shift to the next lower gear.

POTENTIAL HAZARD Shifting gears without releasing the throttle. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always release the throttle when shifting gears.

WARNING

55

CONTROLS AND FEATURES

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.

Important Safeguards S Always back slowly avoiding excessive speed and do not use the

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

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

Light Switches and Indicator Lights

Be careful when operating in reverse. Make certain your path is free of obstacles or and bystanders. Risk of a tip over is greatly increased on hillS. Avoid backing on hills or inclines whenever possible. Tipovers could result causing severe injury or death.

WARNING

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

WARNING

56

CONTROLS AND FEATURES Controls Shifting From Reverse to Forward Be sure machine is completely stopped. Hold the brake lever, raise gear shift pedal one full stroke to engage forward gear. NOTE: neutral is bypassed when shifting from reverse to 1st gear. To engage neutral, depress gear shift pedal one full stroke from the 1st gear position.

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.

POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high. WHAT CAN HAPPEN The wheels could stop rotating. This could cause loss of control, an accident and injury. It could also cause engine or drive train damage. HOW TO AVOID THE HAZARD Make certain the engine has sufficiently slowed before shifting to a lower gear.

WARNING

57

CONTROLS AND FEATURES

Controls Recoil Starter

A

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.

1. Be certain your vehicle is on a level surface and the parking brake is set . See page 74.

2. Take the machine out of gear. 3. Grasp the recoil starter tightly and pull slightly until the starter

mechanism engages. 4. Pull the rope abruptly to start the engine.

Do not extend the starter rope so far that it stops This will cause damage to the recoil assembly. 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.

CAUTION

58

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.

1

2

Do not switch on Demand 4 Drive if the rear wheels are spinning. This may cause severe drive shaft and hub damage.

CAUTION

59

CONTROLS AND FEATURES

Features Exclusive AWD System (All Wheel Drive) Engage the Demand 4 Drive switch before getting into conditions where front wheel drive may be needed. If the rear wheels are spinning, release the throttle before turning the Demand 4 Drive switch on.

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.

NOTE: If the hubs remain engaged after following these instructions return the ATV to your dealer for service.

Switches The light switch is located on the left hand handlebar. In addition to turning the lights on and off, it also switches the lights from Hi to Lo on models equipped with Hi-Lo beams. NOTE: The lights will not work unless the key is in the on position and shut off switch is in the run position.

If both hubs were engaged and only one released during operation, loss of control could result. If you experience hub engaging symptoms, use the above disengaging technique before proceeding. Failure to disengage front hubs as directed above could result in severe injury or death.

WARNING

60

CONTROLS AND FEATURES Features

Indicator Lights

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.

1

2

3

4

61

CONTROLS AND FEATURES

Features Electronic Speedometer

Some Polaris ATVs are equipped with an electronic speedometer which senses vehicle speed from the right hand front wheel. The electronic speedometer measures distance in miles and kilometers as well as hours of operation. 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:

Miles 00000.0 M Trip Miles 000.0 M Hours 00000.0 H

To reset Trip Miles: 1. Toggle to Trip Miles 2. Hold down button approximately 4 seconds. The speedometer also has additional features accessed through a sub-menu. These features are: S Programmable service reminder based on hours S Programmable service reminder based on distance S Change distance measurement from Miles to Kilometers or vice

versa. Each service reminder is set to zero and must be programmed to activate the feature. One or both service reminders can be set. Whichever setting is reached first, the reminder will turn on in the LCD window.

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

CAUTION

62

CONTROLS AND FEATURES Features Electronic Speedometer When the programmed hours are reached, SEr hr will light; when the programmed distance is reached, SErdIS will light. Each time the vehicle is started, the reminder will turn on and remain lit until the button is pushed or the speedometer is reprogrammed for the next service interval.

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:

Service Hours SET hr Service Distance SETdIS Miles to Kilometers COnvrT No Menu Changes DOnE

Changing Distance Measurement 1. Access the sub-menu 2. Select COnvrT and release the button. If the last digit in the

odometer display is K, the current measurement is kilometers; if the last digit is M, distance is being measured in miles.

To Set Service 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

digit flashing. 4. Within 4 seconds, press and release the button to change the digit.

Once the digit is changed once, the button may be held to scroll through the digits from 0 to 9.

5. After the digit has been selected, do not push the button. After 4 seconds the next digit will flash.

63

CONTROLS AND FEATURES

Features Electronic Speedometer

Setting Service Hours (cont.) 6. Repeat step 4 and 5 to program the digits for the service interval

selected. (i.e. for service interval of 50 hours set the display to show: 00050 H)

7. To save the changes press and hold the button when any one of the digits is flashing.

8. The display will change to DOnE. At this time release the button and the changes are now saved.

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

digit flashing. As in the example above, the display would show 00182 H.

4. Either turn the power off or not touch the button for 35 seconds to maintain the current settings.

64

CONTROLS AND FEATURES Features Electronic Speedometer

To Set Service Distance Same as setting Service Hours, but toggle to SET dIS.

To Check When Service Is Due By Distance Same as setting Service Hours, but toggle to SET dIS.

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.

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

WARNING

65

CONTROLS AND FEATURES

Features

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.

66

OPERATION Pre Ride Inspection

Use the following checklist to verify your machine is in proper working order each time you ride.

Item/Inspection Procedure 1. Tires - check condition and pressures 2. Fuel and oil tanks - fill both tanks to their proper levels 3. All brakes - check operation, adjustment and fluid level (includes

auxiliary brake) 4. Throttle - check for free operation and closing 5. Headlight/Taillight/Brakelight - check operation of all indicator

lights and switches 6. Engine stop switch - check for proper function 7. Wheels - check for tightness of wheel nuts and axle nuts; check

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

any area 11. Loose parts - visually inspect vehicle for any damaged components

or loose nuts/bolts or fasteners 12. Operators helmet, goggles and clothing 13. Engine coolant - (Liquid Cooled Models Only) check for proper

level at the recovery bottle

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

WARNING

67

OPERATION

Break-In Period

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

1. Mix 12.8 ounces of injection oil to four gallons (or 16 ounces to 5 gallons) of gasoline in a suitable gas can. Fill the fuel tank as outlined on page 49.

2. Fill the oil tank with Polaris injection oil. 3. Drive slowly at first. Select an area which is open and will give

you room to familiarize yourself with vehicle operation and handling.

4. Vary the throttle positions. 5. Perform regular checks on fluid levels, controls and all important

areas on the vehicle as outlined earlier on the daily pre-ride inspection checklist found on page 66.

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

CAUTION

Do not operate at full throttle or high speeds for extended periods during the first three hours of use. Excessive heat can build up and cause damage to close fitted engine parts.

CAUTION

68

OPERATION Break-In Period After the break in period the oil injection system provides the necessary engine lubrication without the need for pre-mixed fuel.

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.

Fill the oil tank when you refuel your ATV. If you dont serious engine damage could result.

CAUTION

69

OPERATION

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.

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

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

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

4. Vary the throttle positions. Do not operate at sustained idle. 5. Perform regular checks on fluid levels, controls and all important

areas on the vehicle as outlined earlier on the daily pre-ride inspection checklist found on page 66.

6. Pull only light loads. 7. Break in oil and filter. Change at 20 hours or 200 miles.

Use only Polaris Premium 4 All Season synthetic oil, or API certified SH oil. Never substitute or mix oil brands. Serious engine damage and voiding of warranty can result. Do not operate at full throttle or high speeds for extended periods during the first three hours of use. Excessive heat can build up and cause damage to close fitted engine parts.

CAUTION

ADD 8 OZ. NORMAL FULL

Maintain Oil Level In Normal Range

70

OPERATION Starting the Engine Procedure for Starting a Cold Engine

1. Place the transmission in neutral and reset the parking brake.

2. Turn the fuel tank valve to ON. 3. Sit on the vehicle. 4. Pull the choke out all the way. 5. Turn the engine stop switch to

RUN. 6. Turn the ignition key past the

ON position to engage the starter.

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

key or button when the vehicle starts. If engine does not start, release the starter and wait five seconds; then activate the starter for another five seconds. Repeat this procedure until engine starts.

Never run an engine in an enclosed area. Carbon monoxide exhaust gas is poisonous and can cause severe injury or death. Always start engines outdoors.

WARNING

You must allow your vehicle adequate warm up time before operating or engine damage could result.

CAUTION

71

OPERATION

Starting the Engine

After the Engine Starts 1. If the engine slows or stops, use of the choke at half way in will

allow proper engine warm up. 2. Vary the engine RPM slightly with the throttle to aid in warm up

until the engine idles smoothly. Then push the choke all the way in.

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.

72

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.

73

OPERATION

Carrying Loads

2/3 of Load on Rear Rack

1/3 of Load on Front Rack

Important Safeguards To reduce risk of injury or machine damage when carrying loads, read and follow the warnings listed below: S REDUCE SPEED AND ALLOW GREATER DISTANCE

FOR BRAKING WHEN CARRYING CARGO. S CARGO WEIGHT DISTRIBUTION should be 1/3 on the

front rack and 2/3 on the rear rack. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions. Carrying loads on one rack only increases the possibility of vehicle tip over.

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

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

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.

WARNING

74

OPERATION Carrying Loads S LOADS MUST BE CARRIED AS LOW ON THE RACKS

AS POSSIBLE. Carrying loads high on the racks raises the center of gravity of the vehicle and creates a less stable oper- ating condition. When cargo loads are carried high on the racks, the weight of the loads must be reduced to maintain stable operating conditions.

S OPERATE ONLY WITH STABLE AND SAFELY AR- RANGED LOADS. When handling off-centered loads which cannot be centered, securely fasten load and operate with ex- tra caution. Always attach the tow load to the hitch point designated for your ATV.

S EXTREME CAUTION MUST BE USED when operating with loads extending over the rack sides. Stability and ma- neuverability may be adversely affected, causing the machine to overturn.

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

S DO NOT TRAVEL FASTER THAN THE 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.

75

NOISE EMISSION CONTROL SYSTEM REGULATION

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED! U.S. Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery 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

component which conducts removal of engine exhaust gases. 2. Removal or alteration or the puncturing of any part of the engine air

induction system. 3. Replacement of any vehicle parts with parts not in compliance with

federal regulations. 4. Lack of proper maintenance.

S Do not touch exhaust system components. Serious burns can re- sult.

S Be especially careful when traveling through tall grass. The poten- tial for fire exists.

USFS Approved Spark Arrestor Most Polaris ATVs have mufflers that were tested and approved in accordance with the USFS Forest Service Standard 5100-1A. For specific information on your model, see the Owners Manual Specification Supplement that came with your machine.

CAUTION Remember, exhaust system components are very hot dur- ing and after use of ATV. Serious burns can result if hot components are touched.

76

RIDING Pre Ride Inspection

Use the following checklist to verify your machine is in proper working order each time you ride.

Item/Inspection Procedure 1. Tires - check condition and pressures 2. Fuel and oil tanks - fill both tanks to their proper levels 3. All brakes - check operation, adjustment and fluid level (includes

auxiliary brake) 4. Throttle - check for free operation and closing 5. Headlight/Taillight/Brakelight - check operation of all indicator

lights and switches 6. Engine stop switch - check for proper function 7. Wheels - check for tightness of wheel nuts and axle nuts; check that

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

any area 11. Loose parts - visually inspect vehicle for any damaged components or

loose nuts/bolts or fasteners 12. Operators helmet, goggles and clothing 13. Engine coolant - (Liquid CooledModels Only) check for proper level

at the recovery bottle

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

WARNING

77

RIDING

Safe Riding Tips

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

2. After starting the engine and allowing it to warm up, shift the transmission into gear.

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

Vehicle speed is controlled by the amount of throttle opening. 6. Drive slowly, practice maneuvering and using the throttle and brakes

on level surfaces.

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

WARNING

78

RIDING Safe Riding Tips Making Turns

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.

Avoid turning at sharp angles in reverse as tipover and severe injury may result.

WARNING

79

RIDING

Safe Riding Tips Riding On Slippery Surfaces

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

quick, sharp turns which can cause skids. 3. Correct a skid by turning the handlebars in the direction of the skid

and shifting your body weight forward. 4. DrivingwithDemand 4Drive (AllWheelDrive) engagedcan assist in

controlling the vehicle in slippery areas. 5. Never apply brakes during a skid. Complete loss of ATV control can

result. 6. Do not operate on excessively slippery surfaces if possible to avoid. 7. Always reduce speed and use additional caution.

Severe damage to drive train may occur if the Demand Drive is engaged while the wheels are spinning.

CAUTION

Failure to exercise care when operating the ATV on slippery surfaces can be dangerous. Loss of tire traction and vehicle control can result in an accident, including an overturn.

WARNING

80

RIDING Safe Riding Tips Traveling Uphill

25_ Maximum

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

include quick dismounting of the ATV.

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

WARNING

Exercise extreme caution when traveling in hilly terrain. Braking and handling are greatly affected. Loss of vehicle control or overturning of the ATV could occur causing severe injury or death.

WARNING

81

RIDING

Safe Riding Tips Sidehilling

Sidehilling your ATV is one of the most dangerous types of riding and should be avoided if possible. In the event you do enter into a situation where sidehilling is necessary, always: 1. Slow down. 2. Lean into the hill transferring your upper body weight toward the hill

while keeping your feet on the footrests. 3. Steer slightly into the hill to maintain vehicle directions. If vehicle begins to tip, quickly turn the front wheel downhill, if possible, or dismount on the uphill side immediately!

Improperly crossing hills or turning on hills can be dangerous. Loss of vehicle control or overturning of the ATV could occur causing severe injury or death.

WARNING

82

RIDING Safe Riding Tips Traveling Downhill

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

Do not travel at excessive speeds. It is dangerous and can cause loss of vehicle control and tipping, resulting in severe injury or death.

WARNING

83

RIDING

Safe Riding Tips Turning Around On A Hill

8

Uphill

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

uphill. 2. Leave transmission in forward and shut off engine. 3. Dismount on left or uphill side of ATV. 4. Staying uphill of ATV, turn handlebars full left (while facing front

of ATV). 5. While holding service brake, release parking brake lock and slowly

allow ATV to roll around to your right until ATV is pointing across the hill or slightly downward.

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

7. Restart engine with transmission still in forward, release parking brake, and proceed slowly, controlling speed with the service brake, until ATV is on reasonably level ground.

Avoid climbing steep hills. Loss of vehicle control or overturning of the ATV could occur resulting in severe injury or death.

WARNING

84

RIDING Safe Riding Tips Crossing Streams

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

lever until braking action is normal. S Avoid operating the ATV through deep or fast flowing water. If

you cannot avoid water which exceeds the recommended maxi- mum depth, go slowly, balance your weight carefully, avoid sud- den movements, maintain a slow and steady forward motion. Do not make sudden turns or stops and do not make sudden throttle changes.

NOTE: After running the vehicle in water, it is critical your machine is serviced as outlined in the maintenance chart beginning on page 88. The following areas need special attention: engine oil, transmission oil, front and rear gearcases, and all grease fittings.

If your vehicle becomes immersed, and it is impossible to take it to a dealer before starting, follow the steps described on page 154. It is still important the vehicle be serviced by your dealer at the first opportunity.

85

RIDING

Safe Riding Tips Trail Obstacles

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.

Not all obstacles are visible. Travel with caution on trails. severe injury or death can result if your machine comes in contact with a hidden obstacle.

WARNING

86

RIDING Safe Riding Tips

Backing Up 1. Avoid backing up on steep inclines. 2. Always back slowly. 3. When in reverse, apply the brakes lightly for stopping. 4. Avoid turning at sharp angles in reverse. 5. Never open the throttle suddenly while backing. 6. Never activate override button while throttle is open. Loss of

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.

Opening the throttle more than required may cause excessive fuel to build in the exhaust, resulting in engine popping and/or engine damage.

CAUTION

87

RIDING

Safe Riding Tips Parking on an Incline

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

incline, always block the rear wheels on the down hill side as shown above.

5. Shut off fuel supply.

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

WARNING

88

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.

" 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.

Due to the nature of the adjustments marked with aJ on the following chart, it is recommended that service be performed by an authorized Polaris dealer.

CAUTION

89

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule Item Hours or

Miles When Remarks

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

Auxiliary Brake Pre-ride Pre-ride Pre-ride inspection item

Tires Pre-ride Pre-ride Inspect daily, pre-ride in- spection item

Wheels Pre-ride Pre-ride Pre-ride inspection item

Frame nuts, bolts, fasteners

Pre-ride Pre-ride Pre-ride inspection item

Injector Oil Level (2-Cycle)

Pre-ride Pre-ride Check when refueling

" L

Air Filter - Pre-Clean- er

Pre-ride Pre-ride Inspect-Clean

Coolant/Level In- spection

Pre-ride Pre-ride Replace engine coolant every two years

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

Throttle Pre-ride Pre-ride Check operation

Lights Pre-ride Pre-ride Check operation

Engine Stop Switch Pre-ride Pre-ride Check operation

Drive Chain Pre-ride Pre-ride Condition and Slack

Steering Pre-ride Pre-ride Check for free operation

" Air Box Sediment Tube

Pre-ride Pre-ride Drain deposits whenever visible

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

Tail lamp inspection Pre-ride Pre-ride Check operation daily; ap- ply Polaris dielectric grease to socket when re- placed

" L

Air Filter - Main Ele- ment

Weekly Weekly Inspect-Replace if neces- sary

90

MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule

" 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.

Item Hours or Miles

When Remarks

" Transmission Oil Level

20 hrs Monthly Inspect monthly; change annually

Battery 20 hrs Monthly Check Terminals/clean/ check fluid level

Engine Counterbal- ance (400 Engines)

20 hrs Monthly Check oil level; change annually

" L

Engine breather filter (4-cycle)

20 hrs Monthly Inspect--replace annually and as needed

J Brake pad wear 10 hrs Monthly Inspect periodically

" Front and Rear Gear- case Oil (shaft drive)

100 hrs Monthly Check monthly and change annually

Engine Cylinder Head and Cylinder Base Fas- teners

25 hrs 3 months

Inspect (re-torque required at first service only)

" General Lubrication 50 hrs 3 months

Lubricate all fittings, pivots, cables, etc.

" L

Engine Oil - Level/ Change (4-Cycle)

100 hrs / 1000 miles

6 months

Check Level Daily; Break in Service at 1 month. Change oil more often in cold weather use.

Due to the nature of the adjustments marked with a J on the following chart, it is recommended that service be performed by an authorized Polaris dealer.

CAUTION

91

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule Item Hours or

Miles When Remarks

" L

Oil Filter(4-Cycle) 100 hrs / 1000 miles

6 months

Replace with oil change

Oil Pump Cable (2-Cycle)

50 hrs 6 months

Inspect, adjust, lubricate, replace if required

L Engine breather hose (4-cycle)

100 hrs 6 months

Inspect

Carburetor Float Bowl

50 hrs 6 months

Drain bowl periodically and prior to storage

J Throttle Cable/ETC Switch

50 hrs 6 months

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

L Choke (Enricher) Cable

50 hrs 6 months

Inspect-adjust, lubricate, replace if necessary

Coolant strength/ pressure test system

100 hrs 6 months

Inspect strength seasonal- ly; pressure test system annually

" Front hubs/fluid check (AWD)

50 hrs 6 months

Check monthly

Shift linkage 50 hrs 6 months

Inspect, adjust

J Drive belt 50 hrs 6 months

Inspect, replace if neces- sary

" Steering 50 hrs 6 months

Inspect daily, lubricate

" Front Suspension 50 hrs 6 months

Inspect--lubricate, tighten fasteners

" Rear Suspension 50 hrs 6 months

Inspect, tighten fasteners

" Drive Chain(s) 50 hrs 6 months

Inspect daily, adjust and lubricate if needed

L Spark Plug 100 hrs 12 months

Inspect--replace if neces- sary

" Rear Axle 50 hrs 6 months

Inspect bearings, Lube

92

MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule

" 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.

Item Hours or Miles

When Remarks

J L

Ignition Timing 100 hrs 12 months

Inspect and adjust as needed

J L

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.

J Fuel Filter 100 hrs 12 months

Replace annually

Radiator 100 hrs 12 months

Inspect/clean external sur- face

Cooling System hoses

100 hrs 12 months

Inspect

Spark arrestor 100 hrs 12 months

Clean out

" Front hubs/fluid change (AWD)

100 hrs 12 months

J Clutches (drive and driven)

100 hrs 12 months

Inspect, clean

Due to the nature of the adjustments marked with a J on the following chart, it is recommended that service be performed by an authorized Polaris dealer.

CAUTION

93

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule Item Hours or

Miles When Remarks

Engine Mounts 100 hrs 12 months

Inspect

J L

Valve Clearance (4-Cycle)

100 hrs 12 months

Inspect/Adjust

J Injector Oil Filter (2-Cycle)

100 hrs 12 months

Replace

J Shift selector box (H/ L/R)

200 hrs 24 months

Change lubricant every two years

J Brake fluid 200 hrs 24 months

Change every two years

J Front wheel bearings (2wd)

300 hrs 36 months

Inspect, replace if neces- sary

L Idle Speed As Re- quired

As Re- quired

Adjust

Recoil housing As re- quired

As re- quired

Drain moisture out after riding in water

J Toe adjustment As re- quired

As re- quired

Periodic inspection, adjust when parts are replaced

Headlight Aim As re- quired

As re- quired

Adjust if necessary

94

MAINTENANCE AND LUBRICATION Lubrication Recommendations

Item Lube Rec Method Frequency*

1. Engine Oil (2-Cycle)

Polaris Injection Oil

Fill oil tank. See page 49. As needed, when refuel- ing

2.Engine OIl (4-Cycle)

Polaris Premium 4 Synthet- ic 0W40

Add to proper level on dip- stick. See page 105.

Check level daily.

3. Brake Fluid

DOT 3 Only

Maintain level between fill lines. See page 46.

As required; change every two years or 200 hours

4. Transmis- sion Oil

Polaris Premium Synthetic gear case lube

See Page 117 Change annually or at 100 hours

5. Front Gearcase Oil

GL5 80-90 Weight Gear Lube

See Page 122 *Models with Visco drive require special lubricant. See your owners manual sup- plement for requirement.

Change annually or at 100 hours

6. Front Prop Shaft U-joints

Grease+ Locate Fittings and Grease

Every 3 months or 50 hours

7. Front Propshaft Yoke

Grease+ Locate fittings and grease -- 3 pumps maximum

Every 3 months or 50 hours

8. Drive Chain(s)

O-Ring chain lube or SAE 80/90

Lubricate as often as re- quired. Before each ride in wet conditions

As required

9. Demand 4 Hubs - All Wheel Drive ATVs

Premium Hub Lube

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

Annually or at 100 hrs

95

MAINTENANCE AND LUBRICATION Lubrication Recommendations

Operating Range

Full

4. Transmission (dipstick)

6. Front Prop Shaft (U-Joint)

Fill plug

5. Front Gear Case

4. Transmission (plug)

7. Propshaft Yoke

Fill plug

96

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

Grease+ Locate grease fitting and grease with grease gun.

Every 3 months or 50 hours

11. Ball Joint L Grease **

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

Every 3 months or 50 hours

12. Front A Arm Pivot Shaft

L Grease **

Locate fitting on pivot shaft and grease with grease gun.

Every 3 months or 50 hours

13. Counter Balance Housing (400)

SAE 10/30

Check level on dipstick and add oil as necessary. Change annually. To change oil see page 125.

Check monthly and change annually

14. Upper steering Post Bushing

L Grease **

Locate fitting on steering post and grease with grease gun.

Every 3 months or 50 hours

97

MAINTENANCE AND LUBRICATION Lubrication Recommendations

10. Axle Cardan Front Drive (AWD Models)

13. Counterbalance Dipstick

14. Steering Post Bushing

11. Ball Joint

12. Front A-Arm Pivot Shaft

Upper 9. 4 Oclock position

9. Demand 4 Hubs (4x4 only)

98

MAINTENANCE AND LUBRICATION Lubrication Recommendations 15. Rear Axle Bearing

L Grease **

Locate fittings and grease Every 3 months or 50 hours

16. Swing Arm Bushings

L Grease **

Locate fittings on swing arm and grease with grease gun.

Monthly or at 20 hours

17. Upper Control Arms

L Grease **

Locate fittings and grease Semi- annually

18. Lower Control Arms

L Grease **

Locate fittings and grease Semi- annually

19. Rear Wheel Hub Bearing Carri- er

L Grease **

Locate fitting and grease Semi- annually

20. Rear Anti- Roll Bar

L Grease

Locate fitting and grease Semi- annually

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.

99

MAINTENANCE AND LUBRICATION Lubrication Recommendations

16. Swing Arm Bushings

15. Rear Axle Bearing

17. Upper Control Arm

19. Rear Wheel Hub Bearing Carrier

20. Rear Anti- Roll Bar

18. Lower Control Arm

INDEPENDENT REAR SUSPENSION

18. Lower Control Arm

100

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

Maintenance Interval Performed

Servicing Date

Servicing Dealer

or Person

Remarks

First 5 Hrs.

25 Hrs.

50 Hrs.

75 Hrs.

100 Hrs.

101

MAINTENANCE AND LUBRICATION

Engine Cooling System

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.

1

1

A

B

102

MAINTENANCE AND LUBRICATION Engine Cooling System

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.

Never remove the pressure cap when the engine is warm or hot. Escaping steam can cause severe burns. The engine must be cool before removing the pressure cap.

WARNING

1

3

2

A

B

103

MAINTENANCE AND LUBRICATION

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.

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

WARNING

104

MAINTENANCE AND LUBRICATION Lubrication

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.

Premium Gold Synthetic 2-Cycle Oil

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

Premium 2-Cycle Oil

Polaris also has a TC-W3 premium oil available for use in all of our 2 cycle products. We highly recommend its use if premium gold synthetic is not used. The only oil recommended for this ATV is Polaris brand oil. Polaris Premium 2-cycle oils will readily mix with each other, however do not mix Polaris Premium 2-cycle oils with any other oils as they may not be compatible and engine damage may occur.

Engine warranty coverage may become void if you use a brand other than Polaris in your machine.

CAUTION

105

MAINTENANCE AND LUBRICATION

Lubrication

4-Cycle Premium 4 Synthetic Lubricant

Polaris Premium 4 All Season Synthetic engine oil has been specially formulated for use in Polaris 4-cycle engines. It is a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection. Premium 4 possesses unsurpassed film strength over the widest possible temperature range. It resists viscosity and frictional breakdown in ambient temperatures from -40 F to 120 F. Its exceptional frictional properties result 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.

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

CAUTION

106

MAINTENANCE AND LUBRICATION Lubrication Oil Pump Adjustment Procedure 400 Engines 1. Before adjusting the oil pump,

check engine idle RPM and carburetor adjustments which are found in the owners manual supplement.

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.

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

4. Lift boot (1) up off adjuster sleeve (2). Remove the oil pump cover. Loosen the cable adjuster locknut. Adjust oil pump cable until marks align (D) when the throttle slide just begins to raise.

5. Tighten the locknut. 6. Recheck adjustment. If correct, slide boot all the way down over

the upper portion of the bottom nut (3) to ensure good sealing against water entry. Reinstall oil pump cover and gasket.

Oil Pump Adjustment 400

D

1 2 3

107

MAINTENANCE AND LUBRICATION

Lubrication Oil Pump Adjustment Procedure - 250 Engines 1. Before adjusting the oil

pump, check engine idle RPM and carburetor adjustments which are found in the owners manual supplement.

2. Loosen throttle cable jam nut (A) 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.

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

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

Lever

Locknut

Cable Adjuster

Locknut

Lever Arm

108

MAINTENANCE AND LUBRICATION Lubrication Oil Pump Bleeding Procedure 1. Fill the oil reservoir with Polaris injector oil. 2. Loosening the bleeder screw is only necessary when the oil supply

line has been 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.

3. Start the engine and rotate the oil pump lever to its full open position. With the engine at idle, hold the lever up for thirty seconds to make sure all air is out of the system.

Throttle Cable Adjustment 250 and 400 Engines Vehicles with 250 and 400 engines do not utilize a cable sleeve jam nut. You will need to bottom the cable to the carburetor slidevalve cap. Adjust at throttle cable adjuster near the throttle block. See page 137 for adjustment procedure.

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

CAUTION Never run the engine with the bleed screw loose. Loss of oil will cause serious engine damage.

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

CAUTION

109

MAINTENANCE AND LUBRICATION

Lubrication Oil Filter and Change (4-Stroke models with an external oil tank) 1. Place vehicle on a level surface. 2. Clean area around drain plug which is found at the bottom of the

oil tank or on the bottom of the engine. 3. Run engine for two to three minutes until warm. Shut engine off. 4. Place a drain pan beneath the plug and remove it. 5. Allow oil to drain completely. 6. Install a new sealing washer on oil drain plug. NOTE: The

sealing surfaces on the drain plug and the oil tank should be clean and free of burrs, nicks or scratches.

7. Reinstall drain plug and torque to 14-17 ft. lbs. (1.93-2.35 kg/m) 8. Disconnect the lower

oil delivery hose. Remove the fitting (C) from the oil tank. Clean the fitting screen. Reinstall the fitting screen, torquing to 14-17 ft. lbs. Reattach oil line. If banjo fitting (D) is used, torque to 14-17 ft. lbs. If hose clamp (E) is used, tighten to 25 in. lbs.

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

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

OR

A

B

C

C D

E

110

MAINTENANCE AND LUBRICATION Lubrication Oil Filter and Change (Cont.) (4-Stroke models with an external oil tank) 11. Lubricate O-Ring on new filter with a film of new engine oil.

Check to make sure the O-Ring is in good condition. Also make sure the O-ring from the old filter is not still on the engine.

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

13. Approximately 1 cup of engine oil will remain in the crankcase. To drain, 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.

14. Reinstall drain plug. 15. Remove dipstick and add the amount of oil indicated in your

Owners Manual Supplement. Reinstall dipstick. NOTE: If sump is not drained, add about 1 3/4 quarts initially.

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

17. Start engine and let it idle for one to two minutes. Stop engine and inspect for leaks.

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

19. Dispose of used filter and oil properly.

Dipstick

Filter

111

MAINTENANCE AND LUBRICATION

Lubrication Oil Filter and Change Magnum 325 2x4, Magnum 325 4x4, Trail Boss

Oil and Filter Change 1. Place vehicle on a

level surface. 2. Run engine two to

three minutes until warm. Stop engine.

3. Clean area around drain plug.

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

5. Allow oil to drain completely. 6. Replace sealing washer on drain plug. NOTE: The sealing

surfaces on drain plug and crankcase should be clean and free of burrs, nicks or scratches.

7. Reinstall drain plug and torque to 14 ft. lbs. (19 Nm). 8. Place shop towels beneath oil filter. Using an oil filter wrench,

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

make sure the O-ring is in good condition. 11. Install new filter and turn by hand until filter gasket contacts the

sealing surface, then turn and additional 1/2 turn.

Crankcase Drain

112

MAINTENANCE AND LUBRICATION Lubrication Oil Filter and Change (Cont.) Magnum 325 2x4, Magnum 325 4x4, Trail Boss

12. Remove dipstick and fill sump with 2 quarts (1.9 l) of Polaris Premium 4 synthetic oil.

13. Place gear selector in neutral and set parking brake. 14. Start the engine and let it idle for one to two minutes. Stop the

engine and inspect for leaks. 15. Re-check the oil level on the dipstick and add oil as necessary to

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.

113

MAINTENANCE AND LUBRICATION

Lubrication Oil Filter and Change Xpedition 325 1. Place vehicle on a level

surface. 2. Run engine two to

three minutes until warm. Stop engine.

3. Clean area around drain plug.

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

5. Allow oil to drain completely. 6. Replace sealing washer on drain plug. NOTE: The sealing

surfaces on drain plug and crankcase should be clean and free of burrs, nicks or scratches.

7. Reinstall drain plug and torque to 14 ft. lbs. (1.9 kgm). 8. Place shop towels beneath oil filter. Using an oil filter wrench,

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

make sure the O-ring is in good condition. 11. Install new filter and turn by hand until filter gasket contacts the

sealing surface, then turn an additional 1/2 turn. 12. Remove dipstick and fill sump with 4.5 quarts (4.25L) of Polaris

Premium 4 synthetic oil.

Oil Drain

114

MAINTENANCE AND LUBRICATION Lubrication Oil Filter and Change (Cont.) Xpedition 325 13. Shift machine into neutral and set parking brake. 14. Start the engine and let it idle for one to two minutes. Stop the

engine and inspect for leaks. 15. Re-check the oil level on the dipstick and add oil as necessary to

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.

115

MAINTENANCE AND LUBRICATION

Lubrication Oil Filter and Change Xpedition 425 1. Place vehicle on a

level surface. 2. Run engine two to

three minutes until warm. Stop engine.

3. Clean area around drain plug.

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

5. Allow oil to drain completely. 6. Replace sealing washer on drain plug. NOTE: The sealing

surfaces on drain plug and crankcase should be clean and free of burrs, nicks or scratches.

7. Reinstall drain plug and torque to 14 ft. lbs. (1.9 kgm). 8. Place shop towels beneath oil filter. Using an oil filter wrench,

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

make sure the O-ring is in good condition. 11. Install new filter and turn by hand until filter gasket contacts the

sealing surface, then turn an additional 1/2 turn.

Oil Drain

116

MAINTENANCE AND LUBRICATION Lubrication Oil Filter and Change (Cont.) Xpedition 425 12. Remove dipstick and fill sump with 5.5 quarts (5.2 l) of Polaris

Premium 4 synthetic oil. 13. Shift machine into neutral and set parking brake. 14. Start the engine and let it idle for one to two minutes. Stop the

engine and inspect for leaks. 15. Re-check the oil level on the dipstick and add oil as necessary to

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.

117

MAINTENANCE AND LUBRICATION

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).

Model Oil Level A Oil Fill Ounces (ml)

Scrambler 500 4x4 1 5/8 27 (800)

Xplorer 400 1 5/8 27 (800)

Xplorer 4x4 1 5/8 27 (800)

Magnum 500 1 5/8 13.5 (400)

Magnum 325 4x4 1 5/8 13.5 (400)

Magnum 325 2x4 3/4 27 (800)

Magnum 4x4 Shown

1

A

118

MAINTENANCE AND LUBRICATION Lubrication Transmission Oil Changing Procedure 1. Remove the four screws on the footwell and gently pull outward

for access. Remove propshaft shield from the right side of the vehicle (Scrambler 500 4x4, Xplorer 4x4).

2. Remove fill plug. 3. Remove transmission drain plug located on the bottom left hand

side and drain the oil (refer to page 117 for the location of the Magnum drain plug). Catch and discard used oil properly.

4. Clean and reinstall the drain plug torque to 14 ft. lbs. (1.93 kg-m). 5. Add the correct amount of Polaris Premium Synthetic Gearcase

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

1.

119

MAINTENANCE AND LUBRICATION

Lubrication Transmission Lubrication - Models with Dipstick

Transmission Dipstick

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).

120

MAINTENANCE AND LUBRICATION Lubrication 2x4 Models To check the level: 1. Remove fill dipstick and

wipe clean. 2. Reinstall dipstick

completely, remove and check the level. Add the proper lubricant as required to bring level into operating range as shown.

To change lubricant: 1. Remove skid plate (if

necessary). 2. Place a drain pan beneath

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

accumulated metallic filings. 6. After the oil has drained completely, install a new sealing washer

and install the drain plug. Torque to 14 ft. lbs. (19.3 Nm). 7. Turn adjuster bolt (B) out until it touches the frame, and then an

additional 1/2 turn. 8. Tighten the jam nut securely while holding the adjuster bolt. 9. Add the proper lubricant through the dipstick hole until the oil

level is between the upper and lower limits. Do not overfill. 10. Check for leaks. 11. Reinstall skid plate if removed in step 1.

A

B

C

121

MAINTENANCE AND LUBRICATION

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

and drain the oil. Catch and discard used oil properly.

3. Clean and reinstall the drain plug. 4. Add 32 oz. (948 ml) Polaris Premium

Synthetic Gearcase Lubricant (PN 2871478 - 12 oz. bottle) to full mark on the fill plug/dipstick.

5. Check for leaks. Full

Operating Range

122

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.

Gearcase Oil Changing Procedure 1. Remove fill plug (1). 2. Remove gearcase drain plug

located on the bottom right hand side and drain the oil.

3. Clean and reinstall the drain plug and tighten securely (14 ft. lbs/1.93 kgm).

4. Add 4 ounces (120 ml) (Type A) or 5 ounces (150 ml) (Type B) of GL5 80-90 Weight Gear Lube. Visco lock (C), fill with the oil recommended by your owners manual supplment until oil comes out the plug.

5. Reinstall filler plug. 6. Check for leaks.

B

A

1

1

C

1

123

MAINTENANCE AND LUBRICATION

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.

Oil Changing Procedure 1. Remove drain plug (3).

Catch and discard used oil properly.

2. Clean and reinstall the drain plug with a new sealing washer and tighten securely (14 ft. lbs./1.93 kgm).

3. Remove fill plug and add 10 ounces (300 ml of GL5 80-90 Weight gear Lube and inspect oil level. Oil level should be kept even with the center of the drill point (approximately 1 5/8 below the top of the fill hole).

4. Reinstall the fill plug. Tighten securely (14 ft. lbs/1.93 kgm).

5. Check for leaks

1

3

2

1 5/8

124

MAINTENANCE AND LUBRICATION Lubrication Counter Balance Lubrication - 400 Engines

1. Counter Balance Drain

2. Crankcase Drain

3. Recoil Drain

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.

3

2

4

1

125

MAINTENANCE AND LUBRICATION

Lubrication Procedure for Adding Oil 1. Remove seat and locate

dipstick (1). 2. Remove dipstick. Oil level

is shown on dipstick. 3. Add SAE 10W30 oil with a

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

4. Reinstall dipstick. NOTE: Recommended Oil Level (2).

Counter Balance Oil Changing Procedure 1. Remove skid plate. 2. Remove counter balance

drain plug. Catch used oil and discard of properly.

3. Clean and reinstall drain plug.

4. Add 10W30 oil to full mark on dipstick. Capacity after draining is approximately 70-75 cc (2.3 - 2.5 oz.).

5. Reinstall dipstick and check for leaks.

1

1

2

126

MAINTENANCE AND LUBRICATION Lubrication

Oil System The oil tank is located on the left side of the vehicle or on the engine, depending on the model. To check the oil: 1. Set machine on a level

surface. 2. Start the engine and let

it idle for 20-30 seconds.

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

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

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

ADD 8 OZ. NORMAL FULL

Maintain Oil Level In Normal Range

127

MAINTENANCE AND LUBRICATION

Filter Systems Air Cleaner - 2 Cycle Engines

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

required.

Filter Installation Procedure 1. Check condition of airbox and replace if necessary. 2. Replace filter over carburetor boot. Make certain filter is fully

seated in the air box. 3. Tighten clamp. Do not overtighten or filter damage may occur. 4. Check cover gasket and replace if required. Be certain the cover is

seated properly and snap the clips on to the cover. 5. Reinstall ATV seat.

128

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

the clean air side of the filter. 2. If compressed air is used never exceed a pressure of 40 PSI.

Always use a dispersion type nozzle to prevent filter damage and clean from the inside to the outside.

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

Air Filter Service - 4 Cycle 1. Remove seat. 2. Release clips and remove

cover. 3. Loosen clamp and remove

filter 4. Remove fabric type

pre-filter (1) from main filter (2). Wash pre-filter in soapy water and dry it.

5. Reinstall pre-filter over main filter. Replace main filter as required.

6. Reinstall filter into air box and tighten clamp. Do not over tighten clamp or filter damage may occur.

2

1

129

MAINTENANCE AND LUBRICATION

Filter Systems

Breather Filter and Hose 4-Cycle Engines With Dry Sump* 1. Remove the clamps and

pull the filter (1) out of the hoses. NOTE: It will not be necessary to remove the lower hose from the engine.

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

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

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.

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

CAUTION

1

130

MAINTENANCE AND LUBRICATION Adjustments Steering Inspection The steering assembly of the machine should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, have your dealer tighten them before riding your vehicle.

Camber and Caster The camber and caster are non-adjustable.

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

straight ahead position and hold them in this position.

If you determine your machine needs the tie rod adjusted for toe alignment, contact your dealer for service. Steering is a vital part of your machine that, if adjusted wrong, could lead to severe injury or death.

WARNING

131

MAINTENANCE AND LUBRICATION

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

touches side surface of the rear tires on each side of machine and goes around the stands in front of the machine.

4. Measure from string to rim at front and rear of front rim. Rear rim measurement should be 1/16 - 1/8 (.2 to .3 cm) more than front rim measurement.

5. If this measurement needs to be adjusted, contact your dealer for service.

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

WARNING

132

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.

Rear Spring Adjustment Cam

Rear Spring Adjustment

133

MAINTENANCE AND LUBRICATION

Adjustments

Handlebar Adjustment Your ATV has handlebars which can be adjusted for your personal fit. 1. Locate handlebar bolts. On

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

2. Loosen the four bolts. 3. Adjust handlebar to desired

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

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

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

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.

WARNING

134

MAINTENANCE AND LUBRICATION Adjustments Front Brake

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

page 46. Normal functioning of the diaphragm is to extend into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is indicated and the diaphragm should be replaced. Always fill the reservoir as indicated whenev- er the cover is loosened or removed to insure proper diaphragm operation. Use Polaris DOT 3 brake fluid.

S Check brake system for fluid leaks.

S Check brake for excessive travel or spongy feel.

S Check friction pads for wear, damage and looseness.

S Check security and surface condition of the disc.

S Pads should be changed when friction material is worn to 3/64 (.1 cm) (A), or about the thickness of a dime.

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

WARNING

A

135

MAINTENANCE AND LUBRICATION

Adjustments Rear and Auxiliary Brake

Rear Brake The rear brake is a hydraulic disc type brake which is activated by the same lever which activates the front brake system. The rear brake system is self adjusting and requires no maintenance other than periodic checks of the pads for wear. S Pads should be changed when the friction material is worn to 3/64

(.1 cm) which is about the thickness of a dime. S Inspect the brake disc spline and pad wear surface for excessive

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.

136

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

running the vehicle approximately five minutes.

2. Place the transmission in gear with the parking brake applied.

3. Adjust the carburetor idle screw in or out until the desired idle RPM is reached. Turning the screw in (clockwise) will raise RPM. Turning the screw out (counterclockwise) will lower RPM.

The following variations to air screw adjustment for 2-Cycle engines should be noted: S For improving cold weather start and reducing audible detonation

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

S During hot weather and/or high altitude operation the air screw can be adjusted for smooth operation by approximately 2 turns counter- clockwise.

Idle Screw

Air Screw

137

MAINTENANCE AND LUBRICATION

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

running the vehicle approximately five minutes.

2. Place the transmission in gear with the parking brake applied.

3. Adjust the carburetor idle screw (A) in or out until the desired idle RPM is reached. Turning the screw in (clockwise) will raise RPM. Turning the screw out (counterclockwise) will lower RPM.

Throttle Cable Free Play Adjustment Throttle cable free play is adjusted at the handlebar. 1. Slide the boots (B) off inline cable adjuster sleeve(C). Loosen

adjuster locknut (D). 2. Turn adjuster until 1/16 to 1/8 freeplay is achieved at thumb

lever. NOTE: While adjusting freeplay, it is important you flip the throttle lever back and forth.

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

A

BCB D

138

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.

139

MAINTENANCE AND LUBRICATION

Adjustments

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.

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

parking brake. 2. Loosen the wheel nuts slightly. 3. Elevate the side of the vehicle by placing a suitable stand under the

footrest frame. 4. Remove the wheel nuts and remove the wheel.

Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling which could cause an accident resulting in serious injury or death. Follow the safeguards listed below to prevent this type of situation.

WARNING

140

MAINTENANCE AND LUBRICATION Adjustments Wheel Installation 1. With the transmission in

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

2. Attach the wheel nuts and finger tighten them.

3. Lower the vehicle to the ground.

4. Securely tighten the wheel nuts according to the chart found on page 140:

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

Wheel Nut Torque Specifications

Bolt Size Specification

Front 3/8 20 Ft. Lbs.

Rear 3/8 20 Ft. Lbs.

Rear 1/2 50 Ft. Lbs.

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

141

MAINTENANCE AND LUBRICATION

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.

Tire Inspection When replacing a tire always use original equipment size and type.

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

1

142

MAINTENANCE AND LUBRICATION Adjustments 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.

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.

Never wash the chain with a high pressure washer or gasoline. Damage to the O-rings will result, causing premature wear and drive chain failure.

CAUTION

143

MAINTENANCE AND LUBRICATION

Adjustments Rear Drive Chain Slack Adjustment (Models with Concentric Drive)

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.

Never adjust or operate the vehicle with the rear drive chain too loose or too tight as severe damage to the transmission and drive components can result.

CAUTION

3/16-3/8 (.48 cm - .95 cm) Deflection

1

144

MAINTENANCE AND LUBRICATION Adjustments Adjustment Procedure 1. Loosen chain guide. 2. Loosen two eccentric

locking bolts (2). 3. Loosen caliper mounting

bracket bolts located under the axle.

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

5. Roll the ATV forward or back to adjust chain slack to the proper tension.

6. Tighten the eccentric locking bolts to 30 ft. lbs. (9 kg/m) for machines without the hitch and 45 ft. lbs. (13.7 kg/m) for machines with a hitch.

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

the chain. NOTE: The chain is adjusted correctly when the tightest portion of the chain has approximately 3/8 (10mm) of deflection.

10. Position chain guide to allow 1/8 clearance and tighten retaining bolt to 5 ft. lbs. (7Nm).

11. Reinstall chain guards, if removed NOTE: Reposition chain guide to allow 1/8 (.3 cm) clearance between sprocket and guide.

Rear Drive Chain Adjustment

3

2

Proper Splicelink Clip Opening Position

145

MAINTENANCE AND LUBRICATION

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

changes. 2. Transmission convertor modification to adjust for engine

horsepower loss during high altitude operation. Contact your dealer.

3. On 2 cycle models, air screw adjustments can be made to compensate for temperature changes and/or changes in altitude.

4. On 4-cycle models, pilot screw adjustments can be made to compensate for temperature changes and/or changes in altitude.

NOTE: Contact your dealer for altitude adjustments. They have the training and special tools required to perform all necessary modifications for you.

Accessories There are a wide range of Polaris Accessories available for ATVs. Contact your Polaris dealer to find out about the accessories available for your machine.

146

MAINTENANCE AND LUBRICATION Lights - Adjustment - Replacement Headlight Lamp Replacement

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.

NOTE: Bulb is to be positioned so the harness installs into the lamp at the bottom.

4. Reinstall connector.

Keep your headlights and taillights clean. Poor lighting while riding can result in an accident causing severe injury or death.

Do not service while headlight is hot. Serious burns may result. Do not touch a halogen lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot which will shorten the life of the lamp.

WARNING

CAUTION

147

MAINTENANCE AND LUBRICATION

Lights - Adjustment - Replacement High Beam Headlight Adjustment The headlight beam can be adjusted up and down. 1. Place the vehicle on a level surface with the headlight

approximately 25 (7.6 m) from a wall. 2. Measure the distance from the floor to the center of the headlight

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

beam should be aimed 2 (5.1 cm) below the mark placed on the wall in step 2. NOTE: Rider weight must be included on the seat.

5. Loosen pivot bolt and adjust beam to desired position. 6. Tighten nut and bolt. Torque to 60 in. lbs.

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

WARNING

148

MAINTENANCE AND LUBRICATION Lights - Adjustment - Replacement Headlight Lamp Replacement (Trail Blazer) 1. Remove front cover and unplug the light harness. 2. Remove rubber cap from back of headlight to reveal retention

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

housing. 4. Insert new bulb into housing and tighten retention screw, install

rubber cap. 5. Reconnect light harness. 6. Install cover to machine. 7. Properly adjust headlight aim.

Headlight Adjustment 1. Place the vehicle on a

level surface with the headlight approximately 25 (7.6 m) from a wall.

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

3. Start the engine and turn on headlight.

4. Observe headlight aim. The most intense part of the headlight beam should be aimed 8 (20.3 cm) below the mark placed on the wall in step 2. NOTE: Rider weight must be included on the seat.

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.

1

1

149

MAINTENANCE AND LUBRICATION

Lights - Adjustment - Replacement Headlight Lamp Replacement (Gen IV)

1. Using a small flat blade screwdriver, push in on the lock tab 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 of the headlight pod 4. Lift pod cover up. Disconnect speedometer harnesses from

speedometer. Unplug indicator light harness and remove pod cover.

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

sure tab on lamp locates properly in housing.

Snap pins into tabs

Position knob in slot and secure in locking tabs

Slip O-Ring over pin

Adjustment Knob Stop

Route indicator harness over handlebar

150

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

approximately 25 (7.6 m) from a wall. 2. Measure the distance from the floor to the center of the headlight

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

beam should be aimed 2 (5.1 cm) below the mark placed on the wall in step 1. NOTE: Rider weight must be included on the seat.

5. Adjust beam to desired position by turning the adjustment knob.

151

MAINTENANCE AND LUBRICATION

Lights - Adjustment - Replacement Headlight Housing Replacement 1. Using a small flat blade screwdriver, push in on the lock tab

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

of the headlight pod 4. Remove three Phillips screws

at back of headlight pod. 5. Lift pod cover up. Disconnect

speedometer harnesses from speedometer. Unplug indicator light harness and remove pod cover.

6. Unplug headlamp from wiring harness.

7. Remove O-Ring from headlight pivot pins.

8. Pull headlight housing up to release from locking tabs.

9. Lift adjusting knob up to remove from locking tabs.

10. Carefully pull assembly up and out of pod.

11. Reverse steps to install new housing and reassemble pod.

12. Adjust headlight aim by turning adjusting knob.

O-Ring

5 1/8 (13 cm)

Distance from headlamp parting line to end of adjustment knob stop is 5 1/8 (13 cm).

152

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

cover mounting screws. Remove the lense cover and gasket and set aside for reassembly.

2. Remove lamp (A) and replace it with recommended lamp.

3. Test the taillight/brakelight to see that its working.

4. Reinstall the gasket and lens cover (B) removed in step 1.

Indicator Lamp Replacement - Style I 1. Remove the upper headlight pod (Gen 4) or the front cover (Gen 2)

to access the back of the indicator panel. 2. Using a small, straight blade screwdriver, turn the base of the bad

bulb 1/4 turn counter clockwise. 3. Use a needle nose plier or similar tool to pull the lamp out of the

indicator panel housing. 4. Insert the new bulb and seat it by turning it 1/4 turn clockwise. 5. Reassemble pod or front cover.

Indicator Lamp Replace- ment - Style II 1. Remove mounting panel as

required. 2. Unplug light from harness,

depress locking tabs (C) and remove from pod.

3. Install new light and reassemble panel.

B

A

C

153

MAINTENANCE AND LUBRICATION Spark Plugs Check your owners manual supplement for recommended spark plug and gap. The spark plug and its condition is indicative of engine operation. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds. Immediately check the spark plug for correct color.

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.

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 not worn. General causes are excessive oil, use of non-recommended injection oil, improper use of the choke, or incorrect carburetion adjustments.

Spark Plug Removal and Replacement

The spark plug is removed by using the special wrench provided in the tool pouch. Remove the spark plug cap and then the spark plug by rotating counterclockwise. Reverse the procedure for spark plug installation. Torque to 17 ft. lbs. Never deviate from the recommended spark plug as engine damage can occur.

Never attempt to remove a spark plug while the engine is warm. The exhaust system or engine could burn you causing severe injury.

WARNING

154

MAINTENANCE AND LUBRICATION Water Service

If it is impossible to take it to a dealer before starting, follow the steps outlined below. S Move the ATV to dry land or at the

very least, to water below the foot rests.

S Turn the fuel valve to OFF. S Remove the spark plug. S Loosen the carburetor drain screw (1)

or remove bowl drain (2). S For two stroke engines, remove crank-

case drain screw as on page 124. S Turn the engine over several times

with electric start. S Dry the spark plug and reinstall or re-

place with a new plug. S Tighten the carburetor drain screw (1)

or reinstall carburetor drain (2). S Reinstall crankcase drain. S Turn the fuel valve to ON. S Attempt to start the engine. If neces-

sary repeat the drying procedure. S Take the machine to your dealer for

service as soon as possible whether you succeed in starting it or not.

If water has been ingested into the PVT follow the procedure on page 159 to dry out the PVT.

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.

CAUTION

1

2

155

MAINTENANCE AND LUBRICATION Spark Arrestor

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

shown above. 2. Place the transmission in neutral and start the engine. Purge

accumulated carbon from the system by momentarily revving the engine several times.

3. If somecarbon is expelled, cover the exhaust outlet and rapon thepipe around the clean out plugs while revving the engine several more times.

When cleaning the spark arrestor, you must follow the safeguards listed below to avoid serious injury or death.

S Do not perform this operation immediately after the engine has been run because the exhaust system becomes very hot.

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

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

carbon from the spark arrestor. S Never run the engine in an enclosed area. The exhaust con-

tains poisonous carbon monoxide gas. S Do not go under the machine while it is inclined. S Keep combustible materials away from exhaust system. Fire

may result.

WARNING

156

MAINTENANCE AND LUBRICATION

Spark Arrestor (cont.) 4. If particles are still

suspected to be in the muffler, back the machine onto an incline so the rear of the machine is one foot higher than the front. Set the parking brake and block the wheels. Make sure the machine is in neutral and repeat steps 2 and 3.

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.

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

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

8. Reinstall the arrestor plugs.

1

1

1

1

157

MAINTENANCE AND LUBRICATION

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

5. Crankcase Drain 6. Starter Pinion Drain

7. Recoil Drain (above front prop shaft on shaft drive models)

8. Counter Balance Drain (400s)

7

6 8

7

5

5 A

B

158

MAINTENANCE AND LUBRICATION PVT System

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.

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

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

S Routine maintenance is the responsibility of the owner. Al- ways follow recommended maintenance procedures. See your dealer!

S This PVT system is intended for use on Polaris products only.

S The PVT housing must be securely in place during opera- tion.

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

WARNING

159

MAINTENANCE AND LUBRICATION

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.

PVT Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating: First remove the drainplug and allow the water to drain. Replace the drain plug. Start the engine and shift the transmission into neutral. Apply varrying throttle for 10 to 15 seconds. This will expel the moisture and air-dry the belt and clutches. Allow the engine RPM to settle to idle speed and shift the transmission to the lowest available range and test for belt slippage. If the belt slips, repeat the process. Take the vehicle to your dealer for service as soon as possible.

160

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.

Low Range: S Basic operation at speeds less than 7 MPH S Heavy pulling S Riding through rough terrain (swamps, mountains, etc.) at low

ground speeds High Range: S Basic operation at speeds greater than 7 MPH S High ground speeds

161

MAINTENANCE AND LUBRICATION

Battery

Replenishing the Battery Fluid A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. The fluid level should be kept between the upper and lower level marks. To refill use only distilled water. Tap water contains minerals which are harmful to a battery.

Whenever removing the battery, disconnect the negative (black) cable first. When reinstalling the battery, connect the negative (black) cable last or an explosive situation could result causing serious injury or death.

WARNING

Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away. Ventilate when charging or using in an enclosed space. Always shield eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN.

WARNING

Maintain between upper and lower level marks

162

MAINTENANCE AND LUBRICATION Battery Battery Removal 1. Disconnect hold down straps holding the electrical box and battery in

position and remove battery cover. 2. Remove the battery vent tube from the battery. 3. Disconnect the black (negative) battery cable first. 4. Disconnect the red (positive) battery cable next. 5. Lift the battery out of theATV, being careful not to tip it sideways and

spill electrolyte.

Battery Installation and Connections

Battery terminals and connections should be kept free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean rags. Coat the terminals with dielectric grease or petroleum jelly. Be careful not to allow cleaning solution or tap water into the battery.

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

CAUTION

To avoid the possibility of explosion, always connect battery cables in the order specified. Red (positive) cable first; black (negative) cable last. An exploding battery can cause serious injury or death.

WARNING

163

MAINTENANCE AND LUBRICATION

Battery 1. Set the battery in its holder. 2. Install the battery vent tube. It must be free from obstructions and

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

3. First connect and tighten the red (positive) cable. 4. Second connect and tighten the black (negative) cable. 5. Reinstall battery cover and attach the hold down strap. 6. Verify that cables are properly routed.

NOTE: S When your ATV is placed in storage for three months or more, the

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

S Before reusing, take the battery to your dealer for testing and re- charging.

S Power plug leads may need to be bent down so that the battery cov- er may be installed.

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.

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

WARNING

164

MAINTENANCE AND LUBRICATION Side Panel Removal (Gen IV Models) Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times. 1. Remove seat. Grasp

rear of side panel near rear cab. With a quick and firm motion, pull the panel forward and outward to disengage the two rear tabs.

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

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

1

3

2

165

MAINTENANCE AND LUBRICATION

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

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.

Waxing Your ATV can be waxed with any non-abrasive automotive paste wax. Avoid the use of harsh cleaners since they can scratch the body finish.

Certain products, including insect repellants and chemicals, will damage plastic surfaces. Care must be taken when using these products near plastic surfaces.

CAUTION

166

MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips

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.

Do not start the engine during the storage period. This will disturb the protective film created by fogging.

CAUTION

167

MAINTENANCE AND LUBRICATION

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.

168

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

slightly rearward. 2. Remove spark plug(s). Rotate piston to BDC and pour

approximately two ounces of Polaris 2 Cycle Injector oil into the cylinder.

3. Turn the engine over several times to ensure coverage of piston rings, cylinder walls and crankshaft bearings.

4. Treat the fuel system with Polaris Carbon Clean. 5. If Polaris fuel system additive is not used, fuel tank, fuel lines, and

carburetor should be completely drained of gasoline. to eliminate any fuel remaining in the carburetor, run the engine until it stops.

Transporting Whenever the ATV is to be transported the following measures should be taken. 1. Turn off the engine and remove the key. It may be lost if not

removed. 2. Turn the fuel valve to off. 3. Be certain the fuel cap, oil cap, and seat are installed correctly. 4. Always tie the frame of the ATV to the transporting unit securely

using suitable straps or rope. 5. Always place the transmission in gear and lock the parking brake.

169

TROUBLESHOOTING Clutch Drive Belt & Cover Related Issues: Diagnosis

Possible Causes Solutions/What to do

Loading the ATV into a pick- up or tall trailer when in high range.

Shift transmission to low range during loading of the ATV to prevent belt burn- ing.

Starting out going up a steep incline.

When starting out on an incline, use low range, or dismount the ATV after first applying the park brake and per- form the K turn as described on page 83 of this manual.

Driving at low RPM or low ground speed (at approxi- mately 3--7 MPH).

Drive at higher speed or use Low Range. The use of Low Range is high- ly recommended for cooler PVT oper- ating temperatures and longer compo- nent life.

Insufficient warm--up of ATVs exposed to low ambi- ent temperatures.

Warm engine at least 5 min., then with transmission in neutral, advance throttle to approx. 1/8 throttle in short bursts, 5 to 7 times. The belt will be- come more flexible and prevent belt burning.

Slow and easy clutch en- gagement.

Fast, effective use of the throttle for efficient engagement.

Towing/Pushing at low RPM/low ground speed.

Use Low Range only.

Plowing snow, dirt, etc./util- ity use.

Use Low Range only.

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.

170

TROUBLESHOOTING Possible Causes Solutions/What to do

Climbing over large objects from a stopped position.

Shift the transmission to Low Range, carefully use fast, brief, aggressive throttle application to engage clutch. WARNING: Excessive throttle may cause loss of control and vehicle over- turn.

Belt slippage from water or snow ingestion into the PVT system.

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.

Clutch malfunction. For inspection of clutch compo- nents, please contact your Polaris dealer.

Poor engine perfor- mance.

Fouled plugs, foreign material in gas tank, fuel lines, or carburetor. Contact you dealer for further ser- vice information.

GENERAL RANGE OPERATION GUIDELINES:

Low Range Heavy pulling, basic operational speeds less than 7 MPH, riding through rough terrain (swamps, mountains, etc.), low ground speeds.

High Range High ground speeds, speeds above 7 MPH.

171

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.

ENGINE TURNS OVER BUT FAILS TO START

No Fuel Water in Fuel Spark Plug

Fuel Valve Off Drain System No Spark to Spark Plug

Contact Your Dealer

Clogged Fuel Valve or filter

172

TROUBLESHOOTING

ENGINE STOPS OR LOSES POWER

No Fuel

Contact Your Dealer

Contact Your Dealer

Overuse of Choke

Spark Plug Fouled

Engine Overheated

Clean Engine Exterior

Turn Fuel Valve to Res

Water in Fuel

Air Filter Clogged

Reverse Speed Limiter

Malfunction

Electronic Throttle Control Malfunction

Fuel Vent Line Kinked or Plugged

Clean Radiator screen and Radiator Core (liquid cooled models)

173

WARRANTY LIMITED WARRANTY Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty. This warranty begins on the date of purchase. This warranty is transferrable to another consumer during the warranty period through a Polaris dealer. There is a charge of $35.00 payable to Polaris Industries Inc.

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.

174

WARRANTY WARRANTY COVERAGE AND EXCLUSIONS:

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.

175

WARRANTY ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you if inconsistent with controlling state law.

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.

176

INDEX Adjustments 133-148. . . . . . . . . . . . . . . . . . Air Cleaner 127-128. . . . . . . . . . . . . . . . . . . Air Filter / Air Box 128, 169. . . . . . . . . . . . . All Wheel Drive 58-59. . . . . . . . . . . . . . . . . Automatic Transmission 52. . . . . . . . . . . . . Auxiliary Power Outlet 68. . . . . . . . . . . . . . Backing Up 86. . . . . . . . . . . . . . . . . . . . . . . Battery Installation 162. . . . . . . . . . . . . . . . Battery Maintenance 161-163, 170. . . . . . . . Battery Removal 162. . . . . . . . . . . . . . . . . . Brake Fluid 48. . . . . . . . . . . . . . . . . . . . . . . Brake Start 53. . . . . . . . . . . . . . . . . . . . . . . Brake, Auxiliary Mechanical 48, 135. . . . . . Brake, Front 134. . . . . . . . . . . . . . . . . . . . . Brake, Parking 47. . . . . . . . . . . . . . . . . . . . Brake, Rear 135. . . . . . . . . . . . . . . . . . . . . . Brakes 45. . . . . . . . . . . . . . . . . . . . . . . . . . . Brakes, Front 46. . . . . . . . . . . . . . . . . . . . . Brakes, Rear 46. . . . . . . . . . . . . . . . . . . . . . Break- in Period 69-72. . . . . . . . . . . . . . . . . Breather Filter, Sportsman 500

Xplorer 500 129. . . . . . . . . . . . . . . . . Camber and Caster 130. . . . . . . . . . . . . . . . Carburetor Adjustment (4 Cycle) 137. . . . . Carburetor Adjustment (2 Cycle) 136. . . . . Carburetor Adjustments 145. . . . . . . . . . . . Carrying Loads 75-77. . . . . . . . . . . . . . . . . . Chain Adjustment 143. . . . . . . . . . . . . . . . . Choke Lever 44. . . . . . . . . . . . . . . . . . . . . . Cleaning and Storage 165-168. . . . . . . . . . . Cleaning The Main Filter 131. . . . . . . . . . . Controls 46-60. . . . . . . . . . . . . . . . . . . . . . . Coolant Level 101. . . . . . . . . . . . . . . . . . . . Counter Balance Lubrication 124. . . . . . . . Counter Balance Oil Changing

Procedure 125. . . . . . . . . . . . . . . . . . . Crossing Streams 84. . . . . . . . . . . . . . . . . . Cylinder Head Torque 138. . . . . . . . . . . . . Disengaging Wheel Hubs 59. . . . . . . . . . . . Drive Chain Adjustment 142. . . . . . . . . . . . Engine Choke Adjustment 137. . . . . . . . . . Engine Cooling System 101-103. . . . . . . . . Engine Electrical Switches 43. . . . . . . . . . . Engine Idle Rpm Adjustment 137. . . . . . . . Engine Idle Rpm Adjustment 136. . . . . . . . Engine Stop Switch 43. . . . . . . . . . . . . . . . . Features 58-65. . . . . . . . . . . . . . . . . . . . . . . Features and Controls 43-65. . . . . . . . . . . . . Filter Change 108-116. . . . . . . . . . . . . . . . . Filter Systems 127-129. . . . . . . . . . . . . . . . . Fluid Levels 166. . . . . . . . . . . . . . . . . . . . . Fogging The Engine 167. . . . . . . . . . . . . . . Fuel Safety 49. . . . . . . . . . . . . . . . . . . . . . . Fuel Stabilizer 166. . . . . . . . . . . . . . . . . . . . Fuel System 49-51. . . . . . . . . . . . . . . . . . . . Fuel Valve 49. . . . . . . . . . . . . . . . . . . . . . . . Gearcase Oil Changing Procedure 122. . . .

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. . . . . . . . . . . . . . . . . . .

177

INDEX Toe Alignment 130-131. . . . . . . . . . . . . . . . Torque Specifications 140. . . . . . . . . . . . . . Trail Obstacles 85. . . . . . . . . . . . . . . . . . . . Transmission Lubrication 117-119. . . . . . . . Transmission Oil Changing

Procedure 118-121. . . . . . . . . . . . . . . . Transporting 168. . . . . . . . . . . . . . . . . . . . . Traveling Downhill 82. . . . . . . . . . . . . . . . . Traveling Uphill 80. . . . . . . . . . . . . . . . . . .

Troubleshooting 169-172. . . . . . . . . . . . . . . Turning Around On a Hill 83. . . . . . . . . . . . Understanding Warnings 7. . . . . . . . . . . . . Vehicle Identification Numbers 6. . . . . . . . Warranty 173-175. . . . . . . . . . . . . . . . . .