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Sportsman 400/500 HO

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1. 34 40 J Jetting Chart 119 K Key Switch 05 25 K Tuttic ia sie dirt 54 L Lights 2 co ei scoei sce eresise ss 86 89 Headlight Housing Replacement 88 Headlight Lamp 86 High Beam Adjustment 87 Low Beam Adjustment 87 Lower Headlamp Replacement 89 Taillight Brakelight 89 Low Beam Adjustment 87 Low Range Use 96 Lower Headlamp Replacement 89 Lubrication Guide 67 132 M Maintenance Chart 62 66 Master Cylinder 28 Mode Switch 24 Modifications 9 N Noise Emission Control Svstem 61 0 Oil Engine 68 69 Oil Transmission 73 74 Oil and Filter Change 70 72 Oil Level Engine 50 00005 69 Oil Pump Priming 72 Oil Recommendations 68 Operation on Public Lands 61 Override Switch 24 P Parking Brake ci seen 29 Parking on an Incline 60 Periodic Maintenance Chart 62 66 Polaris Product List 117 Polishing the Vehicle 107 Pre Ride Checklist 45 PVT Break In 42 PVT Drying 9 RR net nde 96 PVT SVE users 94 96 R Reverse Operation 57 Reverse Override Switch 24 Rider Information Center 35 40 Riding Ate ie em erre RR 44 Riding G at o oett 8 9 S Safe O
2. MAINTENANCE Oil and Filter Change 12 13 14 15 16 17 18 19 Tip 20 21 22 23 24 Place shop towels beneath the oil filter Using an oil filter wrench turn the filter counter clockwise to remove it Using a clean dry cloth clean the filter sealing surface on the crank case Lubricate the o ring on the new filter with a film of fresh engine oil Check to make sure the o ring is in good condition Install the new filter and rotate it clockwise by hand until the filter gasket contacts the sealing surface then turn it an additional 1 2 turn Approximately one cup of engine oil will remain in the crankcase To drain remove the drain plug on the lower right side of the crank case The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches Reinstall the drain plug Torque to 14 ft Ibs 19 Nm Remove the dipstick Add two quarts 1 9 I of recommended oil Reinstall the dipstick If the sump is not drained add about 1 3 4 quarts 1 6 1 initially Place the transmission in PARK Lock the parking brake Prime the oil pump using the procedure on page 72 Then stop the engine and inspect for leaks Check the oil level Add oil as needed to bring the level to the upper mark on the dipstick Dispose of used filter and oil properly 71 MAINTENANCE Oil and Filter Change Oil Pump Priming This priming procedure must be Tan
3. A Sportsman 400 H 0 A Sportsman 3500 H 0 Owner s Manual for Maintenance and Safety Read this manual carefully It contains important safety information This is an adult vehicle only Operation is prohibited for those under 16 years of age A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm A card containing important ATV safety information should be attached to the owner s manual on the next page If you cannot locate this card or if it has been removed please call 1 800 342 3764 for assistance 00 RECYCLED The text is printed on 10096 recycled with 4096 post consumer waste PCW AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH ALWAYS USE NEVERUSE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control READ OWNER S MANUAL FOLLOW ALL INSTR
4. 1 Usea professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips Avoid the use of harsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 106 MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning not recommended exercise extreme caution The water may damage components and could remove paint and decals Avoid directing the water stream at the follow ing items Wheel bearings Radiator Transmission seals Brakes Cab and body panels Electrical components Switches and controls Labels and decals If an informational or graphic label becomes illegible or comes off con tact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system Polishing the Vehicle POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLA
5. MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the bat tery and result in a shorter life It can also hinder vehicle performance Follow the battery charging instructions on page 101 before installing the battery 1 Ensure that the battery is fully charged 2 Place the battery in the battery holder 3 With conventional batteries install the battery vent tube sealed bat teries do not have a vent tube The vent tube must be free of obstructions and securely installed Route the tube away from the frame and vehicle body to prevent contact with electrolyte WARNING Battery gases could accumulate in an improperly installed vent tube and cause an explosion resulting in serious injury or death Always ensure that the vent tube is free of obstructions and is securely installed as recommended 4 Ne Does NIA On conventional batteries coat the terminals with dielectric grease or petroleum jelly Connect and tighten the red positive cable first Connect and tighten the black negative cable last Install the battery cover if equipped Secure the battery hold down strap Verify that cables are properly routed Cables should be safely tucked away at the front and rear of the battery 99 MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more remove the battery from the vehicle ensure that it s fully
6. Enter the diagnostic mode Toggle to the service interval screen Press and hold the mode button for about 7 seconds until either ON or OFF appears in the Rider Information Center depending on your preference To reset the service interval l 2 3 Enter the diagnostic mode Toggle to the service interval screen Press and hold the mode button for 2 3 seconds until the wrench icon flashes Release the button Press and release the mode button once to advance the setting by one hour Press and hold the mode button to advance the hours quickly If you scroll past the intended number press and hold the button until the hours cycle back to zero When the desired setting is displayed wait until the wrench icon stops flashing The new service interval is now programmed 39 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Miles Kilometers toggle The display in the tripmeter and odometer can be changed to display either standard or metric units of measurement 1 Enter the diagnostic mode 2 Toggle to the screen that displays either kilometers KM or miles MP 3 Press and hold the mode button until the letters flash then press and release the button once When the display stops flashing the mode has been set 40 OPERATION Failure to operate the ATV properly can result in a collision loss of control accident or overturn which may result in serious injury or dea
7. of the disc Clean any grease using a rec ommended brake cleaner or alcohol Do not use spray lubricants or other petroleum based products If you discover any damage cracks excessive corrosion warping see your dealer for service before operating Auxiliary Foot Brake The hydraulic auxiliary brake system requires no adjustment Check the brake fluid level frequently for the auxiliary brake system See page 30 78 MAINTENANCE Toe Alignment Use the following procedure to check the toe alignment of the vehicle The recommended toe alignment is 1 8 to 1 4 3 6 mm toe out WARNING Severe injury or death can result from improper toe alignment and adjustment Do not attempt to adjust tie rod alignment All tie rod adjustments should be performed by an authorized POLARIS dealer 1 Position the vehicle on a level surface y 2 Place the handlebars in a Stand l straight ahead position 3 Tiea length of string between two stands as shown in the illustration Position the stands so that the string is flush with the side of the rear tire If available vou may use a long straight edge instead of string String 4 Measure the distance from the string to the rim at the front 1 and rear 2 of the front rim The rear measurement should be 1 16 1 8 2 3 mm more than the front measurement on each side of the vehicle to obtain the recommended 1 8 to 1 4 3 6 mm toe out alignment 5 Repeat the measurem
8. rm 131 INTRODUCTION The following signal words and symbols appear throughout this manual and on your vehicle Your safety is involved when these words and sym bols are used Become familiar with their meanings before reading the manual A The safety alert symbol indicates a potential personal injury hazard DANGER A DANGER indicates a hazardous situation that if not avoided will result in death or serious injury WARNING A WARNING indicates a hazardous situation that if not avoided could result in death or serious injury CAUTION A CAUTION indicates a hazardous situation that if not avoided could result in minor or moderate injury NOTICE A NOTICE indicates a situation that could result in property damage The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard INTRODUCTION Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death A POLARIS ATV is not a toy and can be hazardous to operate This vehicle handles differently than other vehicles such as motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions e Read this owner s manual Understand all safety warnings precautions and operating procedures be
9. 27 FEATURES AND CONTROLS Master Cylinder Brake Fluid A WARNING An over full master cylinder may cause brake drag or brake lock up which could result in an accident Maintain brake fluid at the recommended level Do not overfill Never store or use a partial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of brake failure which could result in an accident After opening a bottle of brake fluid always discard any unused portion Check the brake fluid in the master Master Cylinder cylinder before each ride 1 Position the ATV on a level surface 2 Position the handlebars so the master cylinder is level 3 View the brake fluid level through the indicator window on the top of the master cylin Indicator der The eye will appear dark Window when the fluid level is full When fluid is low the eye will be clear 4 Ifthe fluid level is low add DOT 4 brake fluid only Do not overfill 28 FEATURES AND CONTROLS Parking Brake Locking the Parking Brake 1 Place the transmission in PARK 2 Squeeze and release the brake lever two or three times then squeeze and hold 3 Push the parking brake lock forward to engage the lock Release the brake lever 5 To release the parking brake lock squeeze and release the brake lever It wil
10. 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 Your ATV may have either a sealed battery which requires little mainte nance or a conventional battery A sealed battery can be identified by its flat covers on the top of the battery A conventional battery has six filler caps on the top of the battery Always keep battery terminals and connections free of corrosion If cleaning is necessary remove corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the termi nals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into a conventional battery 97 MAINTENANCE Battery Battery Removal Disconnect the battery hold down strap Remove the battery cover if equipped On conventional batteries remove the battery vent tube Disconnect the black negative battery cable first Disconnect the red positive battery cable last Lift the battery out of the ATV Be careful not to tip a conventional battery sideways which could spill electrolyte NOTICE f electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle ON pA a E 98
11. D Have an authorized POLARIS dealer perform these services WARNING Improperly performing the procedures marked with a D could result in component failure and lead to serious injury or death Have an authorized POLARIS dealer perform these services 63 MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km Steering Front suspension Rear suspension Tires 7 E Make adjustments as need Brake fluid level Pre Ride ed See Pre Ride Checklist Brake lever travel on page 45 Brake system Wheels fasteners Frame fasteners Engine oil level gt Air filter pre filter Daily Inspect clean often replace E as needed gt Air box sediment Daily Drain deposits when visible tube Coolant Daily Check level daily change coolant every 2 years Headlight taillight Daily Check operation apply worklight dielectric grease if replacing lamps gt Air filter main Weekly Inspect replace as needed E element Recoil housing Weekly Drain water as needed check often if operating in wet conditions b Brake pad wear 10H Monthly 100 160 Inspect periodically D Battery 20H Monthly 200 320 Check terminals clean test gt Engine
12. For questions call POLARIS Customer Assistance United States 1 888 704 5290 Canada 1 204 925 7100 125 WARRANTY U S A EPA Emissions Limited Warranty This emissions limited warranty is in addition to the POLARIS standard limited war ranty for your vehicle POLARIS Industries Inc warrants that at the time it is first pur chased this emissions certified vehicle is designed built and equipped so it conforms with applicable U S Environmental Protection Agency emission regulations POLARIS warrants that the vehicle is free from defects in materials and workmanship that would cause it to fail to meet these regulations The warranty period for this emissions certified vehicle starts on the date the vehicle is first purchased and continues for a period of 500 hours of engine operation 5000 kilo meters 3100 miles of vehicle travel or 30 calendar months from the date of purchase whichever comes first This emissions limited warranty covers components whose failure increases the vehi cle s regulated emissions and it covers components of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this war ranty is the responsibility of the vehicle owner This emissions limited warranty does not cover components whose failure does not increase the vehicle s regulated emissions For exhaust emissions emission related components include any engine parts related to the following systems
13. Front Prop Shaft Yoke 67 MAINTENANCE Engine Oil Oil Recommendations Lubricant Capacity Drain Plug Torque PS 4 PLUS Performance 2 qts 1 9 1 14 17 ft Ibs 19 23 Nm Synthetic 2W 50 4 Cycle Oil Always change the oil filter whenever changing oil POLARIS recommends the use of POLARIS PS 4 PLUS Performance Synthetic 2W 50 4 cycle oil or a similar oil for this engine Oil may need to be changed more frequently 1f POLARIS oil is not used Always use 2W 50 oil Follow the manufacturer s recommendations for ambient temperature operation See page 117 for the part numbers of POLARIS products NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands 68 MAINTENANCE Engine Oil Oil Level Access the oil dipstick and fill tube Dipstick from the left side of the ATV A rising oil level between checks in cool weather driving can indicate contaminants such as gas or mois ture collecting in the crankcase If the oil level is over the full safe mark change the oil immediately 1 Position the vehicle on a level surface 2 Startthe engine Allow it to idle for 20 30 seconds Stop the engine 3 Remove the dipstick Wipe it Safe Range dry with a clean cloth pi 4 Reinstall the dipstick com C gt pletely 5 Remove the dipstick and check the oil level Maintain the oil level in
14. Air induction system Ignition system Fuelsystem Exhaust gas recirculation systems The following parts are also considered emission related components for exhaust emis sions e Aftertreatment devices Sensors Crankcase ventilation valves Electronic control units The following parts are considered emission related components for evaporative emis sions Fuel Tank Vacuum Control Diaphragms Fuel Cap Control Cables Fuel Line Control Linkages Fuel Line Fittings e Purge Valves Clamps Vapor Hoses Pressure Relief Valves Liquid Vapor Separator Control Valves Carbon Canister Control Solenoids Canister Mounting Brackets Electronic Controls e Carburetor Purge Port Connector As related to the evaporative emission control system 126 WARRANTY U S A EPA Emissions Limited Warranty The exclusive remedy for breach of this limited warranty shall be at the exclusive option of POLARIS repair or replacement of any defective materials components or products THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI DENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR RANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTIAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT
15. Drying There may be some instances when water is accidently ingested into the PVT system Use the following instructions to dry it out before operat ing 1 Position the vehicle on a level surface 2 Remove the drain plug Allow the water to drain completely Rein stall the drain plug 3 Start the engine Place the transmission in PARK Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds 5 Allow the engine RPM to settle to idle speed then shift the trans mission to the lowest available range 6 Test for belt slippage If the belt slips repeat the process 7 Take the vehicle to your dealer for service as soon as possible 96 MAINTENANCE Battery A WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last A 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
16. FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PUR POSE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRAN TIES 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 if it is incon sistent with the controlling state law This limited warranty excludes failures not caused by a defect in material or workman ship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or when the vehicle has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of POLARIS Owners are responsible for performing the scheduled maintenance identified in the owner s manual POLARIS may deny warranty claims for failures that have been caused by the owner s or operator s improper maintenance or use by accidents for which POLARIS has no responsibility or by acts of God Any qualified repair shop or person may maintain replace or repair the emission con trol devices or systems on your vehicl
17. High Gear Low Gear Neutral Reverse Park To shift gears brake to a com plete stop When the engine is idling move the lever to the desired gear NOTICE Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage Whenever the ATV is left unattended alwavs place the transmission in PARK and lock the parking brake Belt Life To extend belt life use low forward gear when pulling a heavv load at less than seven miles per hour for extended periods and when operating uphill at a slow speed Gear Selector SEZU T 32 FEATURES AND CONTROLS All Wheel Drive AWD System The All Wheel Drive system is controlled by the AWD switch When the switch is on 2X4 the ATV is in two wheel drive at all times When the switch is on AWD the ATV is in all wheel drive and the AWD indicator light Switch in the instrument cluster will be on When in AWD the demand drive unit will automatically engage any time the rear wheels lose traction When the rear wheels regain traction the demand drive unit will automatically disengage Tip The override switch allows activation of AWD in reverse if the AWD switch is on See page 24 There is no limit to the length of time the vehicle may remain in AWD Engaging AWD The AWD switch may be turned on or off while the vehicle is moving Initially the vehicle s electronic system will not enable the AWD until the engine RPM is be
18. all keys are lost Engine Serial Number SESS l jl 2 Mm amp 6 GI VIN front or rear frame Key Number Vehicle Model Number Frame VIN Engine Serial Number Key Number SAFETY Safety Training ATV safety training is a top priority for POLARIS POLARIS strongly encourages you and any family members who will be riding the ATV to take a training course If you purchased a new POLARIS ATV in the United States your dealer provided information about the authorized ATV RiderCourse that is available to you and your eligible family members This training is included in the purchase price of your ATV You were also provided with printed materials that explain safe operating procedures You should review this information on a regular basis If you purchased a used POLARIS ATV in the United States you can enroll in the ATV RiderCourse for a fee Call ATV Enrollment Express at 800 887 2887 or visit www atvsafety org If you purchased a POLARIS ATV outside the United States please contact your dealer or local law enforcement agencies for information about safety training A POLARIS ATV is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area We strongly advise you to strictly follow the recommended maintenance program outlined in your owner s manual This preventive maintenance program is designed to ensure that all critical
19. cause loss of traction loss of control accident or overturn Always follow proper procedures for turning as described in the owner s manual Never turn abruptly or at sharp angles Never turn at high speeds Practice turning at slow speeds before attempting to turn at faster speeds Jumps and Stunts Attempting wheelies jumps and other stunts increases the risk of an accident or overturn Never attempt wheelies jumps or other stunts Avoid exhibition driving Improper Hill Climbing Improper hill climbing could cause loss of control or overturn Always follow proper procedures for climbing hills as described in the owner s manual See page 51 14 SAFETY Safety Warnings Descending Hills Improperly Improperly descending a hill could cause loss of control or overturn Always follow proper procedures for travel ing down hills as described in the owner s manual NOTE A special technique is required when braking while traveling down hill See page 53 Always descend a hill with the transmission in forward gear Do not descend a hill with the transmission in neutral Always check the terrain carefully before descending a hill Shift your weight rearward Never travel down a hill at high speed Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when possible Crossing Hillsides Driving on a sidehill is n
20. combustion chamber by the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System The emissions from the exhaust of this vehicle are con trolled by engine design including factory set fuel delivery and ignition The engine and related compo nents must be maintained at POLARIS specifications to achieve optimal performance Engine idle speed is the only adjustment POLARIS rec ommends that the operator perform Any other adjust ments should be performed by an authorized POLARIS A dealer Emissions Label MEI NUN MM NN The emissions label is located on the right frame tube Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 This vehicle complies with the EMC requirements of European directives 97 24 EC and 2004 108 EC Non ionizing Radiation This vehicle emits some electromagnetic energy People with active or non active implantable medical devices such as heart monitoring or control ling devices should review the limitations of their device and the applicable electro magnetic standards and directives that apply to this vehicle 61 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest most reliable condition Inspection adjustment and lubrication of important components are explained in the periodic maintenance chart Inspect clean lubricate adjust and replace parts as
21. injury or death NO STEP 7172563 Rack Warning Front and Rear WARNING DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death Tow only from tow hooks or hitch Max Rack Loads Front 90 Ibs 41 kg Rear 180 Ibs 82 kg 7172572 Reverse Override Warning 4X4 Caution WARNING Improper use of override button can lead to loss of control resulting in serious injury or death Do not activate override while throttle is engaged Always apply throttle gradually while in reverse 7175486 23 FEATURES AND CONTROLS Switches Headlight AWD Switch Switch Mode Reverse Main Key Switch Override Engine Choke Switch Stop Switch Mode Reverse Override Switch This vehicle is equipped with a reverse speed limiter system To gain additional wheel speed while backing release the throttle and depress the override button WARNING Pressing the override button while the throttle is open can cause loss of control which may result in serious injury or death Always release the throttle before pressing the override button The override switch is also used to toggle through the modes of the rider information center See page 34 Tip The override switch will not function as a MODE switch if the transmission is in reverse AWD Switch Use the AWD switch to engage 4X4 or 2X4 See page 33 The vehicle automatically engages AWD when operating in reverse if the AWD switch is set to the AWD
22. obstacles are immediately visible Never attempt to operate over large obstacles such as rocks or fallen trees OPERATION Driving in Reverse Follow these precautions when operating in reverse DW pores Der Spar rs Always check for obstacles or people behind the vehicle Always avoid backing downhill Back slowly Apply the brakes ightly for stopping Avoid turning at sharp angles Never open the throttle suddenly Do not use the override button unless additional wheel speed is required for vehicle movement Use the override with caution as rearward vehicle speed is greatly increased Do not operate at wide open throttle Operate the throttle just enough to maintain a desired speed NOTICE Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust resulting in engine popping and or engine damage 57 OPERATION Hauling Cargo A WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability which can result in serious injury or death Always follow these precautions when hauling cargo REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle When determining the weight you are adding to the vehicle include the weight of the operator accessories loads in the rack or box and the load on the trailer tongue The co
23. of the Warranty Registration form to the dealer THE COST OF TRANSPORTA TION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY POLARIS sug gests 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 Mixing oil brands or using non recommended oil may cause engine damage We rec ommend the use of POLARIS engine oil for your ATV 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty SPARK ARRESTER POLARIS warrants that the spark arrester in this vehicle will meet the efficiency requirements of USFS standard 5100 1c for at least 1000 hours when subjected to nor mal use and when maintenance and installation are in accordance with POLARIS rec ommendations 123 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WAR RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCA TION This policy does not apply to vehicles that h
24. position 24 FEATURES AND CONTROLS Switches Engine Stop Switch 4 gt Move the stop switch either left qa or right to the OFF position to ug stop the engine quickly The V engine will not start or run when OFF RUN OFF the switch is off Both the main switch and the engine stop switch will shut off all electri cal power to the vehicle including lights Main Key Switch Use the main key switch to start the engine See page 46 for starting pro cedures Headlight Switch Use the headlight switch to turn the lights on and off and to change the lights from high beam to low beam The key must be in the ON position and the engine stop switch must be in the RUN position to operate the headlights 25 FEATURES AND CONTROLS Throttle Lever A WARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident Never start or operate an ATV that has a sticking or improperly operating throttle Always contact your dealer for service before operating the vehicle Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation Always check the lever for free movement and return before starting the engine Also check occasionally during operation Modifications to the throttle release switch could result in failure to perform as designed which could result in an accident Do not attempt to modify the throttle rele
25. pressure to brake the rear wheels without skidding Brake Fluid Level FOE UM Check the brake fluid level fre quently for the auxiliary brake system The reservoir is located under the seat on the left side of the vehicle Maintain the fluid level between the maximum and minimum marks 30 FEATURES AND CONTROLS Fuel Valve The fuel valve is located in the left front wheel well OFF For vehicle storage and when transporting ON For normal operation Choke The choke assists in starting a cold engine Refer to the engine starting procedure on page 46 for correct choke and throttle settings during starting Fuel Filter The in line fuel filter should be replaced by your dealer after every 100 hours of operation or annually Do not attempt to clean the fuel fil ter Fuel Tank Cap This vehicle is equipped with a digital fuel gauge that will indicate a low fuel condition Refuel when the gauge indicates a low fuel condition Always refuel with the engine stopped and outdoors or in a well venti lated area Refuel on a level surface Remove the fuel tank cap to add fuel to the fuel tank Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Do not use fuel with ethanol content greater than 10 per cent such as E 85 fuel 31 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector is located on the right side of the ABRE
26. to about 1 8 throttle in short bursts 5 to 7 times The belt will become more flex ible and prevent belt burning Slow easv clutch engage ment Use the throttle quickly and effectively Towing pushing at low RPM low ground speed Use low range only Utility use plowing Use low range only Stuck in mud or snow Shift the transmission to low range and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large objects from a stopped position Shift the transmission to low range and carefully use fast brief aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Belt slippage from water or snow ingestion into the PVT system Dry out the PVT See page 96 Inspect clutch seals for damage if repeated leaking occurs Clutch malfunction See your POLARIS dealer Poor engine performance Check for fouled plugs or foreign material in gas tank or fuel lines See your dealer Slippage from failure to warm up belt Always warm up the belt by operating below 30 MPH for one mile 5 miles or more when temperature is below freezing Wrong or missing belt Install the recommended belt Improper break in Always break in a new belt and or clutch See page 42 113 TROUBLESHOOTING Engin
27. type of tires specified for your ATV Always maintain proper tire pressure as described in the owner s manual and on safety labels Operating Over Obstacles Improperly operating over obstacles could cause loss of control or overturn Before operating in a new area check for obstacles Avoid operating over large obstacles such as rocks and fallen trees If unavoidable use extreme caution and always follow proper operating procedures as outlined in this manual See page 57 Skidding or Sliding Skidding or sliding can cause loss of control or overturn if tires regain traction unexpectedly On slippery surfaces such as ice or loose gravel travel slowly and use extra caution to reduce the chance of skidding or sliding Do not operate on excessively slippery surfaces 18 SAFETY Safety Warnings Operating Through Deep Water Operating the ATV through deep or fast flowing water could cause the tires to float causing loss of control or overturn Avoid operating the ATV through deep or fast flowing water If it s unavoidable to enter water that exceeds the recommended maximum depth see page 55 Travel slowly Balance your weight carefully Avoid sudden movements Maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability After leaving water test the brakes Apply them lightly several times while d
28. water or excess fuel in the bottom of the crankcase Water in the bottom of the crankcase can lead to engine damage and must be drained Water accu mulation increases as outside temperature decreases See your POLARIS dealer for engine heater kits which provide quicker warm ups and easier starting in colder weather 47 OPERATION Driving Procedures 2 99 xb ge Ue e D 48 Wear a helmet and eye protection See page 8 Sit upright with both feet on the footrests and both hands on the handlebars Start the engine and allow it to warm up Shift the transmission into gear Check your surroundings and determine your path of travel Release the parking brake Slowly depress the throttle with your right thumb and begin driving Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces OPERATION Turning the Vehicle Your ATV is equipped with fa a solid rear axle which drives both rear wheels RY equally at all times This ANS means that the wheel on the ma i fr ME TA outside of the turn must ii i travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightiv To turn steer in the direc tion of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest This pc c A technique alters the balance of traction between the rear wheels allowing the turn to be made sm
29. 1000 1600 Change fluid normal use gt Rear gearcase oil 100 H 12M 1000 1600 Change fluid gt Transmission oil 100 H 12M 1000 1600 Change fluid D Valve clearance 100 H 12M 1000 1600 Inspect adjust E D Fuel system filter 100 H 12M 1000 1600 Check for leaks at tank cap E lines fuel valve filter pump carburetor replace lines every two years gt Radiator if 100 H 12M 1000 1600 Inspect clean external applicable surfaces gt Cooling hoses if 100 H 12M 1000 1600 Inspect for leaks applicable gt Engine mounts 100 H 12M 1000 1600 Inspect Exhaust muffler 100 H 12M 1000 1600 Inspect pipe D Spark plug 100 H 12M 1000 1600 Inspect replace as needed E D jlgnition timing 100 H 12M 1000 1600 Inspect E gt Wiring 100 H 12M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc 65 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km D Clutches drive 100 H 12M 1000 1600 Inspect clean replace worn and driven parts D Front wheel 100 H 12M 1000 1600 Inspect replace as needed bearings D Brake fluid 200 H 24M 2000 3200 Change every two years Spark arrester 300 H 36M 3000 4800 Clean out Idle speed Adjust as needed D Toe adjustment Inspect periodically adjust when parts are rep
30. AFETY Safety Warnings Operating on Pavement Operating an ATV on paved surfaces including sidewalks paths parking lots and driveways may adversely affect the handling of the ATV and could result in loss of control and accident or overturn Avoid operating the ATV on pavement ATV tires are designed for off road use If it s unavoidable travel slowly and avoid sudden turns or stops Operating on Public Roads Operating this ATV on public streets roads or highways could result in a collision with another vehicle Never operate the ATV on any public street road or highway including dirt and gravel roads In many states it s unlawful to operate ATVs on public streets roads and highways Operating at Excessive Speeds Operating the ATV at excessive speeds increases the operator s risk of losing control Always operate at a speed that s appropriate for the terrain the visibility and operating conditions and your experience 13 SAFETY Safety Warnings Physical Control of the ATV Removing a hand from the handlebars or feet from the footrests during operation can reduce your ability to control the vehicle or cause loss of balance and ejection from the ATV If the operator s foot is not firmly planted on the footrest it could also contact the rear wheels Never remove your hands from the handlebars while operating and always keep both feet on the footrests Turning Improperly Turning improperly could
31. NTENANCE Air Filter Pre Filter 1 Remove the seat Main Filter 2 Release the air box cover clips and remove the air box cover 3 Loosen the clamp and remove the filter es 4 Remove the fabric type pre AN PRS filter from the main filter Wash the pre filter in soapy water then rinse and let drv 5 Reinstall the pre filter over the main filter Install a new main filter if needed d 6 Reinstall the filter into the air bi box and tighten the clamp Do not over tighten the clamp as filter damage could occur 7 Reinstall the air box cover and the seat 83 MAINTENANCE Breather Filter Hose The breather filter is on the hose that runs between the engine and air box See illustration above l 2 4 2 Remove the left side panel See page 80 Remove the hose clamps from the filter and pull the filter out of the hoses Inspect the filter for debris Blow gently through the filter in the direction of the arrow to check for clogging Replace a damaged or clogged filter Check the hoses for cracks deterioration abrasion or leaks Replace as needed Reinstall the filter and hose clamps The filter is effective with the arrow pointing in either direction NOTICE Operation of your vehicle without a breather filter can cause engine 84 damage Always reinstall the breather filter after removing it for service Fuse Replacement If the engine stops or will not start or 1f you experience other elec
32. RIS vehicle Follow the instructions on the container Polishing Tips Avoid the use of automotive products some of which can scratch the finish of your vehicle Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 107 MAINTENANCE Cleaning and Storage Chrome Wheel Care if equipped Proper maintenance will protect chrome wheels from corrosion pre serve wheel life and ensure a like new appearance for many years Chrome wheels exposed to road salt or salt in the air in coastal areas are more susceptible to corrosion if not properly cleaned Clean chrome wheels more often if they re exposed to salt or other corrosive elements 1 Wash chrome wheels frequently Use a mild detergent Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodically Use an automotive grade chrome polish 4 Routinely and liberallv apply a weather resistant wax to each pol ished chrome wheel Choose a product suitable for chrome finishes Read and follow the product labels and instructions Removing Corrosion If light rust is found on the chrome finish use steel wool 0000 OTT grade to remove it Gently rub the affected areas with the steel wool until the corrosion has been removed Clean and
33. Serious engine damage could result Mode Indicator 35 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes Use the MODE button to toggle through the mode options The reverse override button is also the MODE button See page 24 The transmission cannot be in reverse when using this feature Odometer Mode The odometer records the miles traveled by the ATV Trip Meter Mode The trip meter records the miles traveled by the ATV on each trip if it s reset before each trip To reset the trip meter select the trip meter mode Press and hold the mode button override button until the total changes to 0 In the Rider Information Center the trip meter display contains a decimal point but the odometer displays without a decimal point Hour Meter Mode This mode logs the total hours the engine has been in operation Tachometer Mode The engine RPM is displayed digitally Small fluctuations in the RPM from day to day may be normal because of changes in humidity temper ature and elevation 36 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when the gauge is in the diagnostic mode To exit the diagnostic mode turn the key switch off and on Any move ment of the tires will also cause the gauge to exit the diagnostic mode To enter the diagnostics mode l 2 3 4 Turn the key switch off and wait 10 seconds Lock the parking b
34. UCTIONS AND WARNINGS For your nearest Polaris dealer 4 e call 1 800 POLARIS PGLRQHBRIS or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9923790 Rev 01 Printed in USA LIN DLL WELCOME Thank you for purchasing a POLARIS vehicle and welcome to our world wide family of POLARIS enthusiasts Be sure to visit us online at www polarisindustries com for the latest news new product introductions upcoming events career opportunities and more Here at POLARIS we proudly produce an exciting line of utility and recreational products e Snowmobiles All terrain vehicles ATVs e RANGER utility vehicles e Victory Motorcycles Low emission vehicles LEVs We believe POLARIS sets a standard of excellence for all utility and recreational vehicles manufactured in the world today Many years of experience have gone into the engineering design and development of your POLARIS vehicle For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the POLARIS Service Manual and should be performed only by a factory certified Master Service Dealer amp MSD technician Your POLARIS dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for a
35. UN Do not press the throttle while starting the engine OPERATION Starting the Engine 11 Turn the ignition key past the ON position to engage the starter Activate the starter for a maximum of five seconds releasing the key when the engine starts NOTICE Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle 12 If the engine does not start return the key to the OFF position and wait five seconds before attempting to start again Activate the starter for another five seconds if necessary Repeat this procedure until the engine starts Tip If a warm engine has cooled to a point where it does not readily start inter mittent use of the choke button pulled half way out may be necessary If the engine is over choked when warm depress the throttle lever fully while cranking to aid in starting Release the throttle lever immediately after the engine starts If the engine does not start and all conditions are favorable change the spark plug and try again 13 If the engine slows or stops position the choke knob half way in to allow proper engine warm up Vary the engine RPM slightly with the throttle to aid in warm up When the engine idles smoothly push the choke completely in Cold Weather Operation Ifthe ATV is used year round check the oil level frequently A rising oil level could indicate the accumulation of contaminates such as
36. ase switch or replace it with any after market throttle mechanisms Always ensure that the throttle cable is installed and properly routed to the throttle release switch Engine speed and vehicle move ment are controlled by pressing the throttle lever The throttle lever is es spring loaded Engine speed returns maj ES Hm to idle when the lever is released fi DN This ATV is equipped with athrot tle release switch which is Ku dE designed to reduce the risk of a fro wa zen or stuck throttle If the throttle cable should stick in an open posi tion when the operator releases the throttle lever the engine will stop and power to the rear wheels will cease 26 FEATURES AND CONTROLS Brake Lever A WARNING Operating the ATV with a spongy brake lever can result in loss of braking which could cause an accident Never operate the ATV with a spongy feeling brake lever Always contact your dealer for service before operating the vehicle Squeeze the brake lever toward the handlebar to apply the front and rear brakes These brakes are hydraulically activated disc type brakes that are activated by only one lever Always test brake lever travel and master cylinder 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
37. ating on excessively steep hills could cause an overturn Never operate on hills too steep for the ATV or for your abilities Never operate the ATV on hills Steeper than 25 degrees 16 SAFETY Safety Warnings Operating on Slippery Terrain Failure to use extra caution when operating on excessively rough slippery or loose terrain could cause loss of traction loss of control accident or overturn Do not operate on excessively rough slippery or loose terrain Always use extra caution on rough slippery or loose terrain Operating in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions 17 SAFETY Safety Warnings Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or person Always follow proper operating procedures as outlined in this manual See page 57 Before shifting into reverse gear always check for obstacles or people behind the ATV When it s safe to proceed back slowly Improper Tire Maintenance Operating this ATV with improper tires or with improper or uneven tire pressure could cause loss of control or accident Always use the size and
38. ave received authorization for export from POLARIS Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warranty or service bulletin coverage if you have any questions This policy does not apply to vehicles registered to government officials or military per sonnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Bulletins How to Get Service In the Country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer If you move or are traveling within the country where your vehicle was purchased War ranty or Service Bulletin repairs may be requested from any authorized POLARIS dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized POLARIS dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair If You Move If you move to another country be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move Vehicles importa tion rules var
39. breather 25H Monthly 250 400 Inspect clean if needed E filter if equipped gt Engine oil change 25H 1M 250 400 JBreak in oil and filter change gt Demand drive fluid 25 H 1M 250 400 JBreak in oil level check gt Rear gearcase oil 25H 1M 250 400 JBreak in oil level check b Transmission oil 25H 1M 250 400 JBreak in oil level check gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service D Have an authorized POLARIS dealer perform these services 64 Periodic Maintenance Chart MAINTENANCE Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km gt General lubrication 50H 3M 500 800 Lubricate all fittings pivots cables etc Carburetor float 50H 6M 500 800 Drain bowl periodically and bowl prior to storage D Throttle Cable 50 H 6M 500 800 Inspect adjust lubricate E Release Switch replace if necessary D Choke cable 50 H 6M 500 800 Inspect adjust lubricate E replace if necessary E Carburetor air 50H 6M 500 800 Inspect duct for proper seal intake ducts flange ing air leaks Drive belt 50 H 6M 500 800 Inspect adjust replace as needed Cooling system 50 H 6M 1000 1600 Inspect coolant strength seasonally pressure test System yearly b Engine oil change 100H 6M 1000 1600 Change the oil and filter gt Demand drive fluid 100 H 12M
40. chanical failure See your dealer Loose ignition connections Check all connections and tighten Water present in fuel Replace with fresh recommended fuel 114 Engine Pings or Knocks Possible Cause TROUBLESHOOTING Solution Poor qualitv or low octane fuel Replace with recommended fuel Incorrect ignition timing See vour dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Runs Irregulariv Stalls or Misfires Possible Cause Solution Fouled or defective spark plug s Inspect clean and or replace spark plug s Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Throttle release switch malfunction See your dealer Other mechanical failure Possible Lean Fuel Cause Low or contaminated fuel See your dealer Solution Add or change fuel clean the fuel svstem Kinked or plugged fuel tank vent line Inspect and replace Low
41. charged and store it out of the sun in a cool dry place Check battery voltage each month during storage and recharge as needed to maintain a full charge Tip Power plug leads may need to be bent down so that the battery cover can be installed POLARIS recommends maintaining battery charge by using a POLARIS Battery Tender charger or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery 1f the voltage drops below a pre determined point See page 117 for the part numbers of POLARIS products Battery Fluid Conventional Battery A poorly maintained battery will deteriorate rapidly Check the battery Fran b e fluid level often Maintain the fluid level between the upper and lower level marks Add only distilled water Tap water contains minerals that are harmful to a battery 100 MAINTENANCE Battery Battery Charging Conventional Battery 1 Remove the battery from the vehicle to prevent damage from leak ing or spilled electrolyte during charging See page 98 2 Charge the battery with a charging output no larger than 1 10 of the battery s amp hr rating Charge as needed to raise the specific grav ity to 1 270 or greater 3 Reinstall the battery See page 99 Make sure the positive terminal is toward the front of the vehicle Battery Charging Sealed Battery The following battery charging ins
42. components on your vehi cle are thoroughly inspected at specific intervals FOR MORE INFORMATION ABOUT ATV SAFETY in the United States call the Consumer Product Safety Commission at 1 800 638 2772 or visit www cpsc gov visit www atvsafety org or call POLARIS at 1 800 342 3764 SAFETY Safe Riding Gear Always wear appropriate clothing when riding an ATV Wear protective clothing for comfort and to reduce the chance of injury Eye Protection Helmet Gloves Long Sleeves Long Pants Helmet Wearing a helmet can prevent a severe head injury Whenever riding a POLARIS vehicle always wear a helmet that meets or exceeds estab lished safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has 051039 granted approval The approval number and serial 0006 31 number will also be displayed on the label SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection When ever riding a POLARIS vehicle always wear shatterproof goggles or use a shatterproof helmet face shield POLARIS recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is k
43. ct for the terrain avoid littering and always stay on the designated trails Trail Etiquette Always practice good etiquette when riding Allow a safe distance between your vehicle and other vehicles operating in the same area Communicate to oncoming operators by signaling the number of vehi cles in your group When stopping move your vehicle to the edge of the trail as far as possible to allow others to pass safely 44 Pre Ride Checklist OPERATION Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident Always inspect the ATV before each use to make sure it s in safe operating condition protective clothing Item Remarks Page Brake svstem lever travel Ensure proper operation 2 Brake fluid Ensure proper level 28 Auxiliary brake Ensure proper operation 30 Front suspension Inspect lubricate if necessary 67 Rear suspension Inspect lubricate if necessary 67 Steering Ensure free operation Tires Inspect condition and pressure 81 Wheels fasteners Inspect ensure fastener tightness 2 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels a Coolant level if applicable Ensure proper level mi Coolant hoses if applicable Inspect for leaks Throttle Ensure proper operation rd Indicator lights switches Ensure operation 24 Engine stop switch Ensure prope
44. e POLARIS recommends that you contact an authorized POLARIS dealer to perform any service that may be necessary for your vehi cle POLARIS also recommends that you use only Pure POLARIS parts It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle s emission controls Tampering with emission controls is prohibited by federal law If you have any questions regarding your warranty rights and responsibilities please contact the POLARIS Warranty Department at 1 888 704 5290 127 MAINTENANCE LOG Present this section of your manual to your dealer each time your vehicle is serviced This will provide you and future owners with an accurate log of maintenance and ser vices performed DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 128 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 129 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 130 A ACCESSOMES c eod Re p RA 111 Ait Filtet oes A 83 All Wheel Drive System 33 Apparel Protective 12 Auxiliary Foot Brake 78 AWD Switch 24 33 AWD Sy
45. e 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 rac ing 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 Warranty does not apply to parts exposed to friction surfaces stresses environmental conditions and or contamination for which they were not designed or not intended including but not limited to the following items Wheels and tires Finished and unfinished surfaces Suspension components Carburetor Throttle body components Brake components Engine components Seat components Drive belts Clutches and components Hydraulic components Steering components Circuit breakers Fuses Batteries Electronic components Light bulbs Sealed beam lamps Warranty applies to the product only and does not allow for coverage of personal loss Some items are considered consumable meaning they are considered part of normal maintenance or part of completing an effective repair The following items a
46. e Doesn t Turn Over Possible Cause Tripped circuit breaker or blown fuse Solution Reset the breaker Replace fuse Low batterv voltage Recharge the batterv to 12 8 VDC Loose batterv connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Engine Turns Over Fails to Start Possible Cause Out of fuel Solution Refuel Clogged fuel valve or filter Inspect and clean or replace Water is present in fuel Drain the fuel svstem and refuel Old or non recommended fuel Replace with fresh recommended fuel Fuel valve is turned off Turn the fuel valve on Fouled or defective spark plug s Inspect plugs and replace if necessary No spark to spark plug Inspect plugs verify stop switch is on Water or fuel in crankcase Immediately see your POLARIS dealer Overuse of choke Inspect clean and or replace spark plugs Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure See your dealer Engine Backfires Possible Cause Solution Weak spark from spark plug Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with fresh recommended fuel Incorrectiv installed spark plug wires See your dealer Incorrect ignition timing See your dealer Me
47. e vehicle is not thoroughly inspected after operation in water Perform the services outlined in the maintenance chart See page 62 The following areas need special attention engine oil transmission oil demand drive fluid rear gearcase oil and all grease fittings If the vehicle tips or overturns in water or if the engine stops during or after operating in water restarting can result in serious engine damage Transport the vehicle to your dealer for service before restarting the engine If this is not possible follow the vehicle immersion inspection and drying procedures outlined on page 92 then see your dealer for service at the first opportunity 4 After leaving water test the brakes Apply them lightly several times while driving slowly The friction will help dry out the pads If it s unavoidable to enter water deeper than the footrest level Proceed slowly Avoid rocks and obstacles Balance your weight carefully Avoid sudden movements Maintain a steady rate of speed Do not make sudden turns or stops Do not make sudden throttle changes 55 OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles l 2 56 Always check for obstacles before operating in a new area Look ahead and learn to read the terrain Be constantly alert for haz ards such as logs rocks and low hanging branches Travel slowly and use extra caution when operating on unfamiliar terrain Not all
48. ecautions Drive straight uphill Avoid steep hills 25 maximum Always check the terrain carefully before ascending any hill Never climb hills with excessively slippery or loose surfaces Keep both feet on the footrests Shift your weight uphill Proceed at a steady rate of speed and throttle opening Opening the throttle suddenly could cause the ATV to flip over backwards 8 Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle pA VUE oe e Me 51 OPERATION Driving on a Sidehill Sidehilling Driving on a sidehill is not recommended Improper procedure could cause loss of control or overturn Avoid crossing the side of any hill unless absolutely necessary If crossing a sidehill is unavoidable follow these precautions Slow down Avoid crossing the side of a steep hill Shift body weight uphill Keep your feet on the footrests Steer slightiv into the hill to maintain vehicle direction If the vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately gu UN om US E93 ors 52 OPERATION Driving Downhill When driving downhill follow these precautions Avoid steep hills 25 maximum Shift body weight uphill Drive straight downhill Poe pori Slow down Excessive speed when traveling downhill can cause loss of control 5 Squeeze the brake lever gradually Applying the brakes t
49. ecommended fluid as needed to bring the level to the bottom of the fill hole threads 4 Reinstall the fill plug Torque to specification 73 MAINTENANCE Transmission Oil Oil Change 1 Remove the fill plug 2 Place a drain pan under the gearcase Remove the drain plug Allow the oil to drain completely Clean and reinstall the drain plug Torque to specification Add the proper amount of the recommended oil Reinstall the fill plug Torque to specification Check for leaks Dispose of used oil properly Front Gearcase Demand Drive Fluid Always check and change the demand drive fluid at the intervals out lined in the Periodic Maintenance Chart beginning on page 62 Maintain the fluid level at the bottom of the fill hole threads See page 117 for the part numbers of POLARIS products IE YW Fluid Recommendations Gearcase Lubricant Capacity Fill Plug Drain Plug Torque Torque Front Demand Drive PLUS Fluid 9 oz 8 10 ft Ibs 11 ft Ibs Gearcase 265 ml 11 14 Nm 15 Nm The fill plug is located on Fill the right side of the demand drive unit The drain plug is located on the bottom right side of the unit 74 MAINTENANCE Front Gearcase Demand Drive Fluid Fluid Check 1 Position the vehicle on a level surface Remove the fill plug Check the fluid level 2 Add the recommended demand drive fluid as needed to bring the level to the bottom o
50. ect carbu retion adjustments Wet Fouled Spark Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended oil improper use of the choke or incorrect throt tle body carburetor adjustments 91 MAINTENANCE Vehicle Immersion If your vehicle becomes immersed major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine If it s impossible to take your ATV to a dealer before starting it follow the steps outlined below l 2 10 11 12 92 Move the ATV to drv land or at the verv least to water below the footrests Check the air box If water is present drv the air box and replace the filter with a new filter Turn the fuel valve off Remove the spark plug Loosen the carburetor drain screw Turn the engine over several times using the electric start Dry the spark plug Reinstall the plug or install a new plug Tighten the carburetor drain Screw Turn the fuel valve on Drain Screw Attempt to start the engine If necessary repeat the drying pro cedure Take the ATV 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 96 for dry
51. ed Lubricants 2871312 Grease Gun Kit Premium All Season 2871322 Premium All Season Grease 3 0z 89 ml cartridge 2871423 Premium All Season Grease 14 0z 414 ml cartridge 2871460 Starter Drive Grease 2871515 Premium U Joint Lube 3 0z 89 ml cartridge 2871551 Premium U Joint Lube 14 0z 414 ml cartridge 2871329 Dielectric Grease Nyogel Additives Miscellaneous 2871326 Carbon Clean Plus 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 Loctite 565 Thread Sealant 2859044 POLARIS Battery Tender Charger 117 SPECIFICATIONS SPORTSMAN 400 500 H O Gross Vehicle Weight 1200 Ibs 544 kg Maximum Weight Capacity 485 Ibs 220 kg operator cargo accessories Dry Weight 688 Ibs 312 kg 400 696 Ibs 316 kg 500 Fuel Capacity 4 25 gal 161 Engine Oil Capacity 2 qts 1 9 1 Transmission Oil Capacitv 32 oz 948 ml Demand Drive Fluid Capacitv 9 oz 265 ml Coolant Capacitv 2 7 qts 2 5 1 Front Rack Box Capacitv 90 Ibs 40 8 kg Rear Rack Box Capacitv 180 Ibs 81 6 kg Receiver Hitch Tongue 120 Ibs 54 kg Rear rack capacitv and tongue Capacitv weight not to exceed 180 Ibs 81 6 kg Hitch Towing Rating 1225 Ibs 555 7 kg Unbraked Trailer Towing Capacity 1786 Ibs 810 kg Overall Length Width Height 83 in 211 cm 48 in 122 cm M48 in 122 cm Wheelbase 50 5 in 128 3 cm Ground Clearance 11 in 28 c
52. eds Never attempt wheelies jumps or other stunts Never remove your hands from the handle bars while operating and always keep both feet on the footrests Never consume alcohol or drugs before or while operating an ATV Always use the size and type of tires specified for your vehicle Always maintain proper tire pressure Never operate a damaged ATV After any overturn or accident have a qualified service dealer inspect the entire machine for possible damage Never operate the ATV on a frozen body of water unless you have independently verified that the ice is sufficiently thick to support the weight and moving force of the ATV you and your cargo together with any other vehicles in your party Do not touch hot exhaust system components Always keep com bustible materials away from the exhaust system Always remove the ignition key when the vehicle is not in use to prevent unauthorized use 43 OPERATION Know Your Riding Area Tread Lightly Familiarize yourself with all laws and regulations concerning the opera tion of this off road vehicle in your area Respect the environment in which you ride Find out where the designated riding areas are by con tacting your POLARIS dealer a local riding club or local officials Help keep our trails open for recreational vehicle use As an off road enthusiast you represent the sport and can set a good example or a poor example for others to follow Tread lightly Operate with respe
53. eft or right 5 Torque the front two bolts to 10 12 ft Ibs 14 17 Nm then Handlebar torque the rear two bolts A Bolts gap of up to 1 8 3 mm will remain at the rear of the clamp blocks 103 MAINTENANCE Carburetor Your POLARIS ATV is calibrated at the factory for optimal perfor mance at altitudes ranging from zero to 6 000 feet 1800 m and temper atures of 440 degrees F 4 degrees C or higher Above 6000 feet 1800 m the engine air fuel mixture becomes overly rich and the engine loses approximately 3 of its power for each 1000 foot 304 8 m increase in elevation Although this power cannot be regained adjustments to the carburetor and drive system can be made to allow more efficient opera tion Optional jets available from your POLARIS dealer are required for operation above 6 000 feet and temperatures below 440 degrees F 4 degrees C Continuous operation of the engine without proper jetting when required can cause poor performance overheating or PVT or engine damage See your POLARIS dealer for more information about jetting the ATV for conditions in your area Pilot screws are sealed with metal plugs and are serviceable only by POLARIS dealers Carburetor Engine Idle RPM Adjustment Recommended engine idle RPM is 1200 4 200 If the engine idle speed is unsatisfactory and all other conditions are favorable the carbu retor can be adjusted 1 Start the engine and allow it to warm up for approximate
54. ement weather could result in a collision or accident especially if operating on a road or street This ATV is not equipped with highway approved lights Operate this vehicle off road only Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness Clean headlights frequently and replace burned out headlamps promptly Operating a Damaged ATV Operating a damaged ATV can result in an accident After any overturn or accident have a qualified service dealer inspect the entire machine for possible damage including but not limited to brakes throttle and steering systems Physical Skills 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 overturn and loss of control Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle Hot components can cause burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust System Use caution when traveling through tall grass especially dry grass Unauthorized Use of the ATV Leaving the keys in the ignition can lead to unauthorized use of the vehicle which could result in an accident or overturn Always remove the ignition key when the vehicle is not in use 20 SAFETY Safety Decals and Locations Warning labels have bee
55. ent procedure on the other side of the vehicle 6 If you discover improper alignment see your POLARIS dealer for service 79 MAINTENANCE Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts If loose nuts and bolts are found see your POLARIS dealer for service before operating the vehicle Side Panel Removal 1 Remove the seat 2 Grasp the rear of the side panel near the rear cab With a firm motion pull the panel outward to disengage the side panel from the grommet 3 Pull the panel downward and rearward to remove it Step 1 Step 2 Step 3 Footwell Removal 1 Remove the four screws on the bottom of the footwell 2 Usea flat screwdriver or sidecutters to remove the plastic rivets securing the footwell to the fenders 3 Remove the footwell Rivets Screws 80 MAINTENANCE Tires A WARNING Operating your ATV with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle Always use original equipment size and type when replacing tires Refer to the specifications section beginning on page 118 for recom mended tire type size and pressure Tire Tread Depth Always replace tires 1 8 3 mm t when tread depth is
56. ept clean Gloves Off road style gloves with knuckle pads are the best for comfort and protection Boots The best footwear is a pair of sturdy over the calf boots with low heels Clothing Always wear long sleeves and long pants to protect arms and legs Rid ing pants with kneepads and a jersey with shoulder pads provide the best protection Equipment Modifications We strongly recommend that consumers do not install on a POLARIS ATV any equipment that may increase the speed or power ofthe vehicle or make any other modifications to the vehicle for these purposes The warranty on your POLARIS ATV is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power The addition of certain accessories including but not limited to mow ers blades tires sprayers or large racks may change the handling char acteristics of the vehicle Use only POLARIS approved accessories and familiarize yourself with their function and effect on the vehicle SAFETY Safety Warnings A WARNING Failure to operate the ATV properly can result in a collision loss of control accident or overturn which may result in serious injury or death Heed all safety warnings outlined in this section of the owner s manual See the OPERATION section of the owner s manual for proper operating procedures Operating Without Instruction Operating this ATV without proper inst
57. f the fill hole threads 3 Reinstall the fill plug Torque to 8 10 ft Ibs 11 14 Nm Fluid Change 1 Position the vehicle on a level surface Remove the fill plug Place a drain pan under the demand drive unit 2 Remove the drain plug Allow the fluid to drain completely 3 Clean and reinstall the drain plug Torque to 11 ft Ibs 15 Nm Add the recommended fluid See page 74 for capacity Maintain the fluid level at the bottom of the fill hole threads 5 Reinstall the fill plug Torque to 8 10 ft Ibs 11 14 Nm 6 Check for leaks Dispose of used fluid properly 75 MAINTENANCE Cooling System The engine coolant level is controlled or maintained by the recovery system The recovery system components are the recovery bottle the radiator filler neck the radiator pressure cap and the connecting hose As coolant operating temperature increases the expanding heated excess coolant is forced out of the engine past the pressure cap and into the recovery bottle As engine coolant temperature decreases the con tracting cooled coolant is drawn back up from the bottle past the pres sure cap and into the radiator Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air Check the coolant level 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 c
58. for the recom mended spark plug type and gap for your vehicle Torque spark plugs to specification NOTICE Using non recommended spark plugs can result in serious engine damage Always use POLARIS recommended spark plugs Plug Condition Torque Specification New Spark Plug 9 11 ft Ibs 12 15 Nm Previously Installed Spark Plug 17 20 ft Ibs 23 27 Nm Spark Plug Inspection Spark plug condition is indicative of engine operation Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color See page 91 CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection 1 Rotate the spark plug cap 1 4 turn and pull it off the spark plug 2 Using the special wrench provided in the tool pouch rotate the spark plug counter clockwise to remove it 3 Reverse the procedure for spark plug installation Torque to specifi cation 90 MAINTENANCE Spark Plugs Spark Plug Inspection Normal Spark Plug The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indi cates the proper type and heat range for the engine and the service The tip should not be flaky and white A white insulator tip indicates overheating caused by use of an improper spark plug or incorr
59. fore operating a POLARIS ATV Keep this manual with the ATV Never operate an ATV without proper instruction Take a training course This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course European Vibration and Noise The driver perceived noise and hand arm and whole body vibration lev els of this machinery is measured per prEN 15997 The operating conditions of the machinery during testing The vehicles were in like new condition The environment was con trolled as indicated by the test procedure s The uncertainty of vibration exposure measurement is dependent on many factors including Instrument and calibration uncertainty Variations in the machine such as wear of components Variation of machine operators such as experience or physique Abilitv of the worker to reproduce typical work during measurements Environmental factors such as ambient noise or temperature INTRODUCTION Vehicle Identification Numbers Record your vehicle s identification numbers and key number in the spaces provided Remove the spare key and store it in a safe place An ignition key can be duplicated only by ordering a POLARIS key blank using your key number and mating it with one of your existing keys The ignition switch must be replaced if
60. he pod cover and disconnect the speedometer harnesses from the speedometer Unplug the headlamp from the wiring harness 5 Useasmall screwdriver to remove the o rings from the headlight mounting tabs 6 Pull the headlight housing up to release it from the locking tabs 7 Lift the adjusting knob up to remove it from the locking tabs 8 Carefully pull the assembly up and out of the pod 9 Reverse the steps to install the new housing and reassemble the pod The distance from the headlamp parting line to the end of the adjustment knob stop is 5 1 8 13 cm 10 Adjust the headlight aim by turning the adjusting knob 88 MAINTENANCE Lights Lower Headlamp Replacement 1 Turn the back of the headlight harness counter clockwise and pull the harness assembly away from the headlight assembly 2 Remove the headlamp and install the new headlamp 3 Reinstall the harness assembly into the headlight assembly 4 Turn the headlight harness clock wise to secure the headlamp Taillight Brakelight Lamp Replacement 1 Remove the harness connector from the back of the light Connector assembly 2 Turn the lamp counter clock wise to remove it 3 Apply dielectric grease to the socket and install the new lamp Lamp 4 Reinstall the harness connector 5 Test the light for proper operation 89 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 118
61. he rider information center is located in the instrument cluster All seg ments will light up for 2 5 seconds at start up If the instrument cluster fails to illuminate a battery over voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedome ter If this occurs take the ATV to your POLARIS dealer for proper diagnosis l Gear Indicator This 3 4 5 6 indicator displays gear shifter position H High Gear L Low Gear N Neutral R Reverse Gear P Park AWD Indicator This indicator illuminates Lc a when the AWD switch 1 is in the AWD position Engine Hour Display Indicator Service Interval Diagnostic Mode Indicator Low Battery and Over Voltage This warning usually indicates that the ATV is operating at an RPM too low to keep the battery charged It may also occur when the engine is at idle and high elec trical load lights cooling fan accessories is applied Drive at a higher RPM or recharge the battery to clear the warning Odometer Tachometer Tripmeter Hour Meter Fuel Gauge The segments of the fuel gauge show the level of fuel in the fuel tank When the last segment clears a low fuel warning is activated All segments will flash FUEL will display in the LCD and the speedometer needle will blink Refuel immediately Check Engine Warning Indicator The word HOT displays if the engine overheats Do not operate the ATV if this warning appears
62. ight capacity 4 10 cm can result in serious damage to the vehicle and will void your ATV warranty Never install a hitch longer than 4 10 cm Never install automotive accessories on your POLARIS ATV Always install POLARIS approved or equivalent accessories designed for ATV use 59 OPERATION Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 Stop the engine 2 Place the transmission in PARK 3 Lock the parking brake 4 Always block the rear wheels on the downhill side 5 Turn the fuel valve off 60 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine intake or exhaust components as doing so may affect compli ance with U S A EPA noise control requirements 40 CFR 205 and local noise level requirements Operation on Public Lands in the U S A Your POLARIS vehicle has a spark arrester that was tested and qualified to be in accor dance with the USFS standard 5100 1c Federal law requires that this spark arrester be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public lands in the U S A is regulated by 43 CFR 420 Violations are subject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov ecfr Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the
63. ine speed decreases the amount of centrifugal force decreases reducing the amount of belt pinch On POLARIS ATVs the approximate gear ratio difference between high and low range is 1 2 25 This difference in gearing affects the oper ation of the PVT especially at speeds less than 7 MPH 11 km h due to the system s dependence on engine speed For example when operating at a ground speed of 3 MPH 5 km h 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 5 km h 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 too low to provide the pinch needed to prevent belt slip Belt slip is responsible for creating the excessive heat that destroys belts wears clutch components and causes outer clutch covers to fail The air temperature in the clutch cover is substantially reduced by using low range while operating at low ground speeds Reducing the tempera ture inside the clutch cover greatly extends the life of the PVT compo nents belt cover etc 95 MAINTENANCE PVT System When To Use Low Range and High Range Condition Range to Use Operating at speeds less than 7 MPH 11 km h Low Towing heavy loads Low Operating in rough terrain swamps mountains etc Low Operating at speeds greater than 7 MPH 11 km h High PVT
64. ing out the PVT MAINTENANCE Spark Arrester A WARNING Failure to heed the following warnings while servicing the spark arrester could result in serious injury or death Never run the engine in an enclosed area Remove any combustible materials from the area Wear eye protection and leather work gloves Do not stand behind or in front of the vehicle while purging Never go under the vehicle while it s inclined The exhaust system can get extremely hot Do not perform service on the spark arrester while the system is hot Allow components to cool sufficiently before proceeding Use the following procedure to periodically purge accumulated carbon from the exhaust pipe muffler 1 Remove the arrester clean out plug from the bottom of the muffler 2 Place the transmission in patron QE PARK h m Q 3 Start the engine A Ee 4 Quickly squeeze and release Clean Out Plug mes the throttle lever several times to purge carbon from the system 5 Ifcarbon comes out of the exhaust cover or plug the exhaust outlet Wear protective gloves 6 Lightly tap on the exhaust pipe with a rubber mallet while repeating step 4 7 Ifparticles are still suspected to be in the muffler elevate the rear of the vehicle one foot 30 cm higher than the front Block the wheels 8 Repeat steps 4 to 6 until no more particles are expelled 9 Stop the engine Allow the arrester to cool 10 Reinstall the arrester plug and remove the exhaust ou
65. ion and may promote corrosion and oxidation Accessories Auxiliary power outlets provide 12 volt power for operating accesso ries Accessory outlets are available for all models POLARIS also has a wide range of additional accessories available for your ATV Always install accessories that are approved for ATV use Please see your POLARIS dealer 111 MAINTENANCE Transporting the ATV Follow these procedures when transporting the vehicle 1 Stop the engine 2 Place the transmission in PARK 3 Lock the parking brake Secure the fuel cap oil cap and seat 5 Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front UN Le A arm bolt pockets racks or handlebars 6 Remove the key to prevent loss during transporting l 1 di 112 TROUBLESHOOTING Drive Belt Wear Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range during loading Starting out going up a steep incline Use low range or turn around using the K turn see page 54 Driving at low RPM or ground speed 3 7 MPH Drive at a higher speed or use low range more frequentiv See page 96 Insufficient warm up at low ambient tempera tures Warm the engine at least 5 minutes With the transmission in neutral advance the throttle
66. k 5 Reinstall the pressure cap Use of a non standard pres sure cap will not allow the recovery system to function properly Contact your dealer for the correct replacement part 6 Reinstall the access panel and secure the front box cover 77 MAINTENANCE Brakes Hand Brake The front and rear brakes are hydraulic disc brakes activated by moving the single brake lever toward the handlebar These brakes are self adjusting Under normal operation the diaphragm extends into the reservoir as fluid level drops If the fluid level is low and the diaphragm is not extended a leak 1s likely and the diaphragm should be replaced To ensure proper diaphragm operation always fill the reservoir as needed whenever the cover is loosened or removed Do not overfill WARNING An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill The following checks are recommended to keep the brake system in good operating condition Check more often if brakes are used heavily under normal operation 1 Always keep brake fluid at an adequate level See page 28 Check the brake system for fluid leaks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness Replace brake pads when they are worn to 3 64 1 mm 5 Check the security and surface condition 3 64 1 mm
67. k performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected 1 Clamp or pinch off the vent line approximately 2 5 cm from the oil tank between the end of the oil tank vent fitting and the fa Pressure vent line s pressure relief slit Relief Slit 2 Start the engine Allow it to idle for 10 20 seconds 3 Remove the vent line clamp If the line is bled properly you should hear a rush of air indicating that the line is properly primed and ready for operation Tip If you do not hear air the line has not bled Repeat the priming procedure 72 MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 62 Maintain the oil level at the bottom of the fill plug hole threads See page 117 for the part numbers of POLARIS products The fill plug is located on the left side of the ATV under the rear fender behind the wheel The drain plug is located on the right side of the gearcase on the right side of the ATV behind the wheel well Fill Plug Drain Plug Transmission Oil Recommendations Lubricant Capacity Fill Plug Drain Plug Torque Torque AGL PLUS Transmission Fluid 32 oz 20 25 ft Ibs 20 25 ft Ibs 946 ml 27 34 Nm 27 34 Nm Oil Check 1 Position the vehicle on a level surface 2 Remove the fill plug Check the oil level 3 Add the r
68. l return to its unlocked position WARNING Operating the ATV while the parking brake is engaged could result in an accident or fire Always check to be sure the parking brake is disengaged before operating The parking brake may relax if left on for a long period of time Always block the wheels to prevent rolling Always block the wheels on the downhill side of the ATV if leaving it parked on a hill Another option is to park the ATV in a sidehill position Never depend on the parking brake alone if the ATV is parked on a hill Always block the wheels to prevent rolling 29 FEATURES AND CONTROLS Auxiliary Foot Brake A WARNING Never back down a hill Applying the auxiliary brake when backing down a hill may cause rear tipover which could result in serious injury or death Use caution when applying the auxiliary brake Do not aggressively apply the auxiliary brake when going forward The rear wheels may skid and slide sideways causing loss of control and serious injury or death The auxiliary brake system is intended to be used as a backup for the main brake system Should the main system fail use the auxiliary foot brake Since this is a rear brake only it will not be as effective as the all wheel single lever system The auxiliary foot brake is located Auxiliary Foot Brake on the inside of the right footrest Operate this brake with your right foot If the rear wheels slide while using the auxiliary brake reduce brake pedal
69. laced Headlight aim Adjust as needed gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service D Have an authorized POLARIS dealer perform these services 66 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri odic Maintenance Chart beginning on page 62 Items not listed in the chart should be lubricated at the General Lubrication interval The a arms and lower control arms are lubricated at the factory and no additional lubrication will be needed However if these components are subjected to severe use grease zerks have been provided for additional lubrication at the user s discretion Item Lube Capacity at Inspection Procedure Fluid Change Engine Oil PS 4 PLUS 2 qt 1 91 Maintain level in safe range Performance on dipstick See page 69 Synthetic 2W 50 Brake Fluid DOT 4 Only Maintain level between fill lines See page 28 Transmission Oil JAGL PLUS 32 oz 948 ml Maintain level at bottom of fill Transmission Fluid hole threads See page 73 Demand Drive Demand Drive 9 oz 265 ml Maintain level at bottom of fill Fluid Plus Fluid hole threads See page 74 Front Gearcase Front Prop Shaft POLARIS Pre Grease fittings 3 pumps Yoke mium U Joint Lube maximum every 500 miles before long periods of stor age or after pressure wash ing or submerging
70. ll of your ser vice needs during and after the warranty period POLARIS POLARIS and SPORTSMAN are registered trademarks of POLARIS Industries Inc Copyright 2012 POLARIS Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited The original instructions for this vehicle are in English Other languages are provided as translations of the original instructions Printed in U S A 2013 SPORTSMAN 400 500 HO Owner s Manual P N 9923790 TABLE OF CONTENTS Introduction ss i bia ore mmm Ek Re 4 Safety 25 2x cdi dora dicet PES Edd gg E 7 Features and Controls 24 Operation 2exe terere io f 41 Emission Control Systems 61 Maintenance a uice o ex seer Ro dose RR e a 62 Troubleshooting 2299 Rx REOR 113 POLARIS Products 117 Specifications oro o ERI x 118 Warranty A EN 120 Maintenance Log ssss 128 lur 56s iain
71. low 3100 Once enabled the AWD remains enabled until the AWD switch is turned off If the switch is turned off while the demand drive unit is moving it will not disengage until the rear wheels regain traction Engage the AWD switch before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to AWD 33 FEATURES AND CONTROLS Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel In addition to showing vehicle speed the speedometer needle flashes when a warning condition exists The instrument cluster measures distance in miles as well as hours of operation It also includes a reverse speed limiter function that limits the ATV s speed to approximately 7 9 MPH 11 14 km h Refer to page 24 for additional information Speedometer Needle Speedometer Rider AN i E Information Center NOTICE High water pressure may damage ATV components Wash the ATV by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage the speedometer lens and other plastic surfaces Do not use alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens Immediately clean off any gasoline that splashes on the instrument cluster 34 FEATURES AND CONTROLS Instrument Cluster Rider Information Center T
72. ly and shift weight uphill REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent loss of control avoid Discretionary sudden braking or sharp turns r 7175511 Y Tire Pressure Load Warning WARNING Improper tire pressure or overloading can cause loss of control Loss of control can result in severe injury or death Cold tire pressure Front 5 0 psi 34 5 kPa Rear 5 0 psi 34 5 kPa Maximum weight capacity 485 Ibs 220 kg 7175642 Hitch Capacity Label TRAILER MAX WEIGHT 1225 LBS 557 KG ON LEVEL GROUND HITCH MAX VERTICAL WEIGHT 120 LBS 55 KG 7174159 No Passenger Warning WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH 7175378 Age 16 Warning WARNING 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 7175374 22 SAFETY Safety Decals and Locations General No Passenger Warning Warning Rack Rack i honing Warning Hitch Capacity Clutch Cover Tire Pressure Load Warning Warning Clutch Cover Warning WARNING 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
73. ly five ista minutes Place the transmission in gear Lock the parking brake Turn the screw in clockwise to raise RPM Turn the screw out counter clockwise to lower RPM Po Idle Screw 104 Throttle Cable Freeplay MAINTENANCE Adjust throttle cable freeplay at the handlebar l 2 Locate the throttle cable adjuster at the handlebar Squeeze the end of the rub ber boot and slide it far enough to expose the end of the inline cable adjuster Loosen the adjuster lock nut Rotate the boot to turn the adjuster until 1 16 to 1 8 1 5 3 mm of freeplay is achieved at the thumb lever While adjusting freeplay be sure to flip the throttle lever back and forth Tighten the lock nut Squeeze the end of the rub ber boot and slide it over the cable adjuster to its original position Boot Lock Nut Adjuster 105 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your POLARIS vehicle clean will not only improve its appear ance but it can also extend the life of various components NOTICE High water pressure may damage components POLARIS recommends washing the vehicle by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage plastic surfaces Do not allow these types of products to contact the vehicle The best and safest way to clean your POLARIS vehicle is with a gar den hose and a pail of mild soap and water
74. m Minimum Turning Radius 65 in 165 cm unloaded Engine EH46PLE 400 EH500PLE 500 Displacement 455 cc 400 498 cc 500 Bore x Stroke 87 9x75mm 400 92 x 75mm 500 Alternator Output 260 w Compression Ratio 10 1 1 400 10 2 1 500 Carburetor 34mm Mikuni 400 40mm Mikuni 500 Pilot Jet 42 5 400 40 500 Main Jet 160 400 150 500 Needle Jet P 6M 829 400 X 6M 500 Jet Needle 41B33 3 400 6MGHI 194 500 Pilot Screw By flow taper 12 5 Brass Plug Ignition System Digital CDI Ignition Timing 30 2 5000 RPM Spark Plug Gap NGK BKR6E 035 in 0 9 mm Lubrication System Dry Sump Driving System Type Automatic PVT POLARIS Variable Transmission Front Suspension MacPherson strut with 8 2 21 cm travel Rear Suspension Progressive rate with 9 5 24 cm travel Shift Type Side Lever H L N R P Based on EU Directive 76 432 EC 118 SPECIFICATIONS SPORTSMAN 400 500 H O Gear Reduction Low 23 91 1 Gear Reduction Reverse 21 74 1 Gear Reduction Forward 10 57 1 Drive Ratio Front 3 82 1 Tires Pressure Front 25x8 12 5 psi 34 5 kPa Tires Pressure Rear 25x10 12 5 psi 34 5 kPa 400 500 25x11 12 5 psi 34 5 kPa 500 LE Brakes Front Rear Single Control Hydraulic Disc Brake Auxiliary Foot Activa
75. mbined weight of these items must not exceed the maximum weight capacity 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 only one rack increases the possibility of vehicle overturn CARRY LOADS 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 operating condition SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing downhill USE EXTREME CAUTION when operating with loads that extend over the rack sides Stability and maneuverability may be adversely affected causing the vehicle to overturn DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the front rack DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS NEVER exceed 50 MPH 80 km h when rear cargo loads are above 75 Ibs 34 kg and or fron
76. n placed on the vehicle for your protection Read and follow the instructions on each label carefully If any of the labels shown in this manual differ from the labels on your vehicle always read and follow the instructions of the labels on the vehicle If an informational or graphic label becomes illegible or comes off con tact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge The part number is printed on the label General Warning WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate without proper training or instruction atspeeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS 7175376 21 SAFETY Safety Decals and Locations Discretionary Warning WARNING Never operate this ATV on HILLS steeper than 25 degrees 25 To pre vent overturn on hilly terrain use throttle and brakes gradual
77. necessary When inspection reveals the need for replacement parts use genuine POLARIS parts available from your POLARIS dealer Record maintenance and service in the Maintenance Log beginning on page 128 Service and adjustments are important for proper vehicle operation If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average rid ing conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use must be inspected and ser viced more frequently Severe Use Definition Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crank case Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer 62 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key Symbol Description Perform these operations more often for vehicles subjected to severe use E Emission related service failure to conduct this maintenance will not void the emissions warranty but may affect emissions
78. octane fuel Replace with recommended fuel Clogged fuel filter Replace filter Incorrect fuel Replace with recommended fuel Incorrect jetting Possible Rich Fuel Cause Fuel is verv high octane See your POLARIS dealer Solution Replace with lower octane fuel Overuse of choke Inspect clean and or replace spark plugs Stopping starting without adequate warm up Allow engine to warm up before operat ing and or stopping Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Incorrect jetting See your POLARIS dealer 115 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel cycle key to ON position three times for 5 seconds each then start Kinked or plugged fuel vent line Inspect and replace Overuse of choke Inspect clean and or replace spark plugs Water is present in fuel Replace with new fuel Fouled or defective spark plug s Inspect clean and or replace spark plug s Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfuncti
79. oe Alignment 79 Towing Loads 59 Trail Etiquette 0 2 cee eee eee 44 Training eresse cet ete teris 7 Transmission 00 32 Transmission Oil 73 74 Transporting the ATV 112 Tread Lightly 44 Turning Around on aHill 54 Turning the Vehicle 49 V Vehicle Identification Numbers 6 Vehicle Immersion 92 jun 6 Ww Warning Symbols 4 Washing the Vehicle 106 107 Wheel Hub Tightening 81 Wheel Installation 82 Wheel Nut Torque Specifications 82 Wheel Removal 81 133
80. ompatible anti freeze coolant and distilled water POLARIS Premium 60 40 is already premixed and ready to use Do not dilute with water See page 117 for the part numbers of POLARIS products Always follow the manufacturer s mixing recommendations for the freeze protection required in your area Recovery Bottle Coolant The recovery bottle is located on the left side of the vehicle 1 Remove the left side panel See page 80 2 Maintain the coolant level between the minimum and maximum marks on the bottle when the fluid is cool 3 Add coolant as needed Recovery Bottle 76 MAINTENANCE Cooling System Radiator Coolant To ensure that the coolant maintains its ability to protect the engine POLARIS recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water Replace the coolant any time the cooling system has been drained for maintenance or repair If the recovery bottle has run dry check the level in the radiator Add coolant as needed CAUTION Escaping steam can cause burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 1 Open the front box cover y u 2 Remove the access panel screws Squeeze the outer edges of the panel inward to remove the panel Mia 3 Remove the pressure cap Radiator je Cap 4 Using a funnel slowly add coolant through the radiator filler nec
81. on See your dealer Throttle release switch malfunction See your dealer Other mechanical failure See your dealer Overheated engine Clean radiator screen and core clean engine exterior see your dealer Engine Overheating Possible Cause Solution Debris lodged in screen Remove and clean the screen Pull on the top portion of the screen then remove the lower portion Plugged Radiator Use a garden hose to flush any debris from the radiator fins NOTE High pres sure washers can deform the radiator fins and reduce cooling efficiency Obstructed cooling fan Clean any debris or mud that may be interfering with fan movement 116 Part POLARIS PRODUCTS Number Description Engine Lubricant 2870791 Fogging Oil 12 oz Aerosol 2876244 PS 4 PLUS Performance Synthetic 2W 50 4 Cycle Oil qt 95 1 2876245 PS 4 PLUS Performance Synthetic 2W 50 4 Cycle Oil gal 3 8 l Gearcase Transmission Lubricants 2878068 AGL PLUS Transmission Fluid qt 95 I 2878069 AGL PLUS Transmission Fluid gal 3 8 l 2877922 Demand Drive Plus Fluid qt 95 I 2877923 Demand Drive Plus Fluid gal 3 8 l 2870465 Pump for Gallon 3 8 I Jug 2871654 Premium Demand Drive Hub Fluid 8 0z 237 ml 2872277 Premium Demand Drive Hub Fluid 2 5 gal 9 5 I Coolant 2871323 60 40 Coolant gal 3 8 1 2871534 60 40 Coolant qt 95 I Grease Specializ
82. oo firmly may cause the rear wheels to lock which could result in loss of con trol 53 OPERATION Turning Around on a Hill K Turn If the vehicle stalls while climbing a hill never back it down the hill Use the K turn to turn around 54 Stop and lock the parking brake while keeping body weight uphill Leave the transmission in forward and shut off the engine Dismount on the uphill side of the vehicle or on the left if the vehi cle is pointing straight uphill Staying uphill of the vehicle turn the handlebars full left While holding the brake lever release the parking brake lock and slowly allow the vehicle to roll around to your right until it s point ing across the hill or slightly downward Lock the parking brake Remount the vehicle from the uphill side keeping body weight uphill Start the engine with the transmission still in forward Release the parking brake and proceed s owly controlling speed with the brake lever until the vehicle 1s on more level ground OPERATION Driving Through Water Your ATV can operate through water with a maximum recom za mended depth equal to the bot f tom of the footrests Follow these procedures when operat ing through water 1 Determine water depths and current before entering water 2 Choosea crossing where both banks have gradual inclines 3 Avoid operating through deep or fast flowing water NOTICE Major engine damage can result if th
83. oothly The same leaning tech nique should be used for turning in reverse Practice making turns at slow speeds before attempting to turn at faster speeds WARNING Turning improperly can result in vehicle overturn Never turn abruptly or at sharp angles Never turn at high speeds 49 OPERATION Driving on Slippery Surfaces Sideways Turn in direction skid of skid COeCO COeCco S7 NANY L5 KS LA O Co C S BS COemC Q4 7 Whenever riding on slippery surfaces such as wet trails or loose gravel or during freezing weather follow these precautions 1 Do not operate on excessively rough slippery or loose terrain 2 Slow down when entering slippery areas 3 Engage AWD before wheels begin to lose traction NOTICE Severe damage to drive train may occur if the AWD is engaged while the wheels are spinning Allow the rear wheels to stop spinning before engaging AWD or engage AWD before wheels begin to lose traction 4 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 5 Never apply the brakes during a skid Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward 50 OPERATION Driving Uphill 25 Maximum Braking and handling are greatly affected when operating in hilly ter rain Improper procedure could cause loss of control or overturn When ever traveling uphill follow these pr
84. or workmanship Warranty period will vary regionally POLARIS also gives a one year limited warranty on the final drive chain 1f equipped 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 transferable to another consumer during the warranty period through a POLARIS dealer 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 No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment 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 120 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 damag
85. ot recommended Improper procedure could cause loss of control or overturn Avoid crossing the side of any hill unless absolutely necessary If crossing a hillside is unavoidable always follow proper procedures as described in the owner s manual See page 52 Never attempt to turn the ATV around on any hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 54 15 SAFETY Safety Warnings Stalling While Climbing a Hill Stalling rolling backwards or improperly dismounting while climbing a hill could cause an overturn Always maintain a steady speed when climbing a hill If all forward speed is lost Keep body weight uphill Apply the brakes Lockthe parking brake when fully stopped Dismount on uphill side or to either side if ATV is pointed straight uphill Turn the ATV around and remount following the procedure described in the owner s manual See page 54 If the ATV begins rolling downhill Keep body weight uphill Never apply engine power Never apply the rear brake while rolling backwards Apply the single lever brake gradually When fully stopped apply the rear brake as well and then lock the parking brake Dismount on uphill side or to either side if ATV is pointed straight uphill Turn the ATV around and remount following the procedure described in the owner s manual See page 54 Operating on Steep Hills Oper
86. peration Practices 43 Safety Decals san sce 21 23 Safety Labels No Passenger Warning 22 Age 16 Warning 22 Clutch Cover Warning 23 Discretionarv Warning 21 General Warning 21 Rack Warning Front and Rear 23 Reverse Override Warning 23 Tire Pressure Load Warning 22 Safety Training 7 Safety Warnings 10 20 Service Interval Programming 39 Severe Use css dssise cot nae hae 62 Side Panel Removal 80 Sidehilling 52 Signal Words 4 Spark Arrester 0 93 Spark Plug Inspection 90 91 Spark Plug Recommendations 90 Spark Plug Torque Specification 90 Spark Plugs 90 91 Specifications 118 119 Spring Adjustment Rear Shock 103 Starting the Engine 46 47 Steering Assembly 80 Storage s csa se n e ra 106 111 Storage Tips 109 111 Switches AWD Switch 24 33 Engine Stop Switch 25 Headlight Switch 25 Main Key Switch 25 Mode Reverse Override Switch 24 INDEX T Taillight Lamp Replacement 89 Throttle Cable Freeplay Adjustment 105 Throttle Lever sess 26 Tire Tread Depth 81 TITE S e ek x eR EEPPEPERQS 81 82 Wheel Installation 82 Wheel Nut Torque 82 Wheel Removal 81 T
87. placement 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 DESCRIP TION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTIAL INCIDENTAL AND SPECIAL DAM AGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE 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 incon sistent with controlling state law ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR 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 limi tations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law 122 WARRANTY 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
88. polish the wheel as out lined above 108 MAINTENANCE Cleaning and Storage Storage Tips NOTICE Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur Never start the engine during the storage period Clean the Exterior Make any necessary repairs and clean the vehicle as recommended See page 106 Stabilize the Fuel 1 Fillthe fuel tank 2 Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer Follow the instructions on the container for the recom mended amount Carbon Clean removes water from fuel svstems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust svstems 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the fuel in the tank and carburetor 4 Turn the fuel valve off 5 Drain the carburetor bowl Oil and Filter Change the oil and filter See page 70 Air Filter Air Box l oo and clean or replace the pre cleaner and air filter See page Clean the air box 3 Drain the sediment tube 4 Clean or replace the breather filter See page 84 109 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 62 Demand drive unit front gearcase Rear gearcase if equipped Transmission Brake fluid change every two years and any
89. r operation 25 Air filter pre filter Inspect clean 83 Air box sediment tube Drain deposits whenever visible Headlamp Eu operation apply POLARIS 25 ielectric grease when lamp is 86 replaced Brake light taillight Check operation apply POLARIS 89 dielectric grease when lamp is replaced Riding gear Wear approved helmet goggles and 8 45 OPERATION Starting the Engine l 2 3 Tip Tip 9 10 46 Position the vehicle on a level surface outdoors or in a well venti lated area Place the transmission in PARK Lock the parking brake The starter interlock will prevent the engine from starting if the transmission is in gear and the brake is not engaged Turn the fuel valve on Sit on the vehicle Do not use the choke if starting a warm engine Excessive use of the choke can cause the spark plug to become wet fouled If the engine is cold pull the choke knob out until it stops The variable choke is fully on when the knob is pulled com pletely out The choke is off when the knob is pushed completely in The choke can be adjusted gradu ally depending on how much choke is needed for starting Be sure the choke is off during opera tion as excess fuel washing into the engine oil will increase wear on engine components If the knob doesn t stay where positioned increase the ten Tension sion by rotating the tension Adjusting Nut adjusting nut clockwise Move the engine stop switch to R
90. rake Place the transmission in neutral Hold the mode reverse override button and turn the key switch on Release the switch as soon as the display is activated Use the mode button to toggle through the diagnostic screens 37 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Battery Voltage Screen View this screen to check battery voltage level Tachometer Screen View the tachometer to check engine speed AWD Diagnostic Screen The gauge indicates whether or not current is flowing through the AWD coll only on models with switchable AWD This screen is for informa tional purposes only Please see your dealer for all major repairs Gear Circuit Diagnostic Screen This screen displays the resistance value in ohms being read at the gear switch input of the gauge This screen is for informational purposes only Please see your dealer for all major repairs Programmable service interval When the hours of engine operation equal the programmed service interval setting the wrench icon will flash for 5 seconds each time the engine is started When this feature is enabled it provides a convenient reminder to perform routine maintenance See page 39 The service interval is programmed at 50 hours at the factory 38 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Programmable service interval To enable or disable the service interval l 2 3
91. re excluded from warranty coverage in the event of a warranty claim Spark Plugs Lubricants such as oil grease etc Filters Batteries unless defective Fuel Cosmetic damage repair Sealants Coolants Hotel fees Meals Towing charges Shipping handling fees Mileage Product pick up delivery Rentals Loss of product use Loss of vacation personal time 121 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES This warranty also excludes failures resulting from improper lubrication improper engine timing improper fuel surface imperfections caused by external stress heat cold or contamination operator error or abuse improper component alignment tension adjustment or altitude compensation failure due to snow water dirt or other foreign substance ingestion contamination improper maintenance modified components use of aftermarket components resulting in failure unauthorized repairs repairs made after the warranty period expires or by an unauthorized repair center use of the product in competition or for commercial purposes Warranty will not apply to any product which has been damaged by abuse accident fire or any other casualty not determined a defect of materials or workmanship 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 re
92. riving slowly The friction will help dry out the pads Improper Cargo Loading Overloading the ATV or carrying towing cargo improperly may cause changes in handling which could cause loss of control or an accident 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 a greater dis tance for braking NEVER exceed 50 MPH 80 km h when rear cargo loads are above 75 Ibs 34 kg and or front cargo loads are above 37 Ibs 17 kg Always follow the instructions in the owner s manual for carrying cargo or pull ing a trailer See page 59 19 SAFETY Safety Warnings Operating on Frozen Bodies of Water Operating on frozen bodies of water may result in serious injury or death if the ATV and or the operator fall through the ice Never operate the ATV on a frozen body of water unless you have indepen dently verified that the ice is sufficiently thick to support the weight and moving force of the ATV you and your cargo together with any other vehicles in your party Variances in snow depth and or water currents may result in uneven ice thickness Always check with local authorities and residents to confirm ice condi tions and thickness over your entire route ATV operators assume all risk associ ated with ice conditions on frozen bodies of water Poor Visibility Operating the ATV in darkness or incl
93. ruction increases the risk of an accident The operator must understand how to operate the ATV properly in different situations and on different types of terrain Beginning and inexperienced operators should complete the recommended safety training before operating this vehicle See page 7 Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age Even though a child may be within the recommended age group for operating some ATVs he she may not have the skills abilities or judgment needed to operate an ATV safely and could be susceptible to accident or injury 10 SAFETY Safety Warnings Handling Gasoline Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always refuel with the engine stopped and outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the area where refu eling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Turn the fuel valve off whenever the vehicle is stored or parked Exposure to Exhaust Engine exhau
94. st fumes are poisonous and can cause loss of consciousness or death in a short time Never start the engine or let it run in an enclosed area The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas Failure to Inspect Before Operating Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident Always inspect the ATV before each use to make sure it s in safe operating condition Always follow all inspection and maintenance procedures and schedules described in the owner s manual 11 SAFETY Safety Warnings Protective Apparel Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a serious injuries in the event of an accident Operator and passenger must always wear an approved helmet that fits properly and eye protection goggles or face shield Using Alcohol or Drugs Operating the ATV after consuming alcohol or drugs could adversely affect operator judgment reaction time balance and perception Never consume alcohol or drugs before or while operating an ATV Carrying a Passenger Carrying a passenger greatly reduces the operator s ability to balance and control the ATV which may result in an accident or overturn Never carry a passenger on this ATV 12 S
95. stem es ces deg rx 33 B Battery oves ves eR men 97 102 Charging Conventional 101 Charging Sealed 101 102 Fluid Conventional 100 Installation 99 Removals cscs tree 98 Storag o m 100 Belt Life ione rhe ee tee 32 13 0 0 Rm 9 Brake Fluid Auxiliary Foot Brake 30 Brake Fluid Main Brake System 28 Brake Lever 0005 27 Brake Foot ees 30 78 Brake Hand Lever 78 Brake Parking 29 Brakelight Lamp Replacement 89 Brak s 2elnexse m exe 3E 78 Break In Period 41 42 Breather Filter 84 Breather Hose 0000 00 84 C Camber Adjustment 103 Carburetors 2 ou ness wines 104 Carburetor Adjustment 104 digo ce Se RD 58 59 Caster Adjustment 103 Choke ores atta od eee eter 31 Chrome Wheel Care 108 Cleaning and Storage 106 111 Clothing il ka di wee ua nons 9 Clutching Chart 119 Consumer Product Safety 7 C Coolant Bottle 76 Coolant Radiator 77 Cooling Svstem 76 77 Corrosion Removal Chrome 108 Crankcase Emission Control System 61 D Demand Drive Capacities 74 Drive Belt Wear Bum 113 Drivetrain Break In 42 Driving Downhill 53 Driving in Reverse 57 Driving on a Sidehill 32 Dri
96. t and install the new lamp Make sure the tab on the lamp locates properly in the housing 8 Reassemble the pod 86 MAINTENANCE Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward Use the following procedure to make the adjustment h i 2 6 em 1 Position the vehicle on a level surface with the headlight approxi matelv 25 ft 7 6 m from a wall Place the transmission in PARK 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 Turn the headlight switch to high beam 4 Observe the headlight aim on the wall The most intense part of the headlight beam should be two inches 5 cm below the mark on the wall Include rider weight on the seat when measuring 5 The adjustment knob is located on the right side of the headlight pod Adjust the beam to the desired position by turning the knob either clockwise or counter clockwise Low Beam Adjustment The low beam can be adjusted slightly upward or downward Phillips Screw 1 Loosen the phillips screw located at the rear of the headlamp 2 Tilt the headlamp upward or down ward 3 Tighten the screw 87 MAINTENANCE Lights Headlight Housing Replacement 1 Remove the two screws on the lower front corners of the headlight pod Lift the pod slightly while depressing the tabs at the rear of the pod 3 Liftt
97. t cargo loads are above 37 Ibs 17 kg Vehicle should never exceed 10 MPH 16 km h while towing a load on a level surface Vehicle speed should never exceed 5 MPH 8 km h when towing loads in rough terrain while cornering or while ascending or descending a hill 58 OPERATION Hauling Cargo Never exceed the weight capaci ties specified for your ATV on warning labels and in the speci fications section of this manual Cargo weight should be evenly distributed 1 3 on the front rack and 2 3 on the rear rack and mounted as low as possible NEVER exceed 50 MPH 80 km h when rear cargo loads are above 75 lbs 34 kg and or front cargo loads are above 37 Ibs 17 kg When operating over rough or hilly terrain reduce speed and cargo weight to maintain stable driving conditions Do not obstruct the headlight beam with cargo Use low forward gear when hauling or towing heavy cargo to extend belt life Towing Loads Always attach a towed load to the hitch point Remove the hitch from the ATV when not towing a trailer If towing a load reduce rear rack cargo weight by the amount of tongue weight The combination of rear rack cargo weight and tongue weight must not exceed the rear rack capacity The total load operator accessories cargo and weight on hitch must not exceed the maximum weight capacity of the vehicle NOTICE Using an improper hitch or exceeding Maximum the maximum tongue we
98. ted Hydraulic Disc Brake Parking Hydraulic lock all wheel Headlight 1 Single Beam on Headlight Pod 50 watt 2 Single Beam on Bumper 50 watt Taillights 8 26 watts Brake Light 26 9 watts Instrument Cluster LCD Jetting Chart AMBIENT TEMPERATURE ALTITUDE a Meters Feet Below 40 F 40 F and above Below 5 C 5 C and above 400 500 400 500 0 1800 0 6000 167 5 155 160 150 1800 3700 155 147 5 150 142 5 6000 12000 Clutching Chart 400 500 Altitude Shift Drive Clutch Driven Helix and Weight Spring Clutch Spring Spring Setting Meters 0 1800 10 WHF Blue Green Black 41 37 Feet 0 6000 PN 5632283 PN 7041157 PN 7041782 PN 5132344 2 2 1800 3700 10 RH Blue Green Black 41 37 6000 12000 PN 5630709 PN 7041157 PN 7041782 PN 5132344 or 20 40 242 PN 5631356 Clutching Chart 500 LE Altitude Shift Drive Driven Helix Weight Clutch Clutch Spring Spring Meters 0 1800 10 WH Blue Green Red EBS Feet 0 6000 PN 5632283 PN 7041157 PN 3234451 PN 3234356 1800 3700 10 RH Blue Green Red EBS 6000 12000 PN 5630709 PN 7041157 PN 3234451 PN 3234356 EBS models require no helix spring adjustment 119 WARRANTY LIMITED WARRANTY POLARIS Sales 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
99. th Read and understand all safety warnings outlined in the safety section of this owner s manual Break In Period The break in period for your new POLARIS ATV is the first 20 hours of operation No single action on your part is as important as following the procedures for a proper break in Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components NOTICE Excessive heat build up during the first three hours of operation will damage close fitted engine parts and drive components Do not operate at full throttle or high speeds during the first three hours of use 41 OPERATION Break In Period Engine and Drivetrain Break in 1 Fill the fuel tank with gasoline See page 31 Always exercise extreme caution whenever handling gasoline 2 Check the oil level on the dipstick See page 69 Add oil if neces sary to maintain the level between the safe and add marks 3 Drive slowly at first Select an open area that allows room to famil larize yourself with vehicle operation and handling Vary the throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 45 6 Pull only light loads 7 Change both the oil and the filter at 25 hours 8 Check fluid levels of transmission and all gearcases after the first 25 hours of operation and ever
100. the safe range Do not overfill Add Oil Safe 69 MAINTENANCE Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 62 Always change the oil filter whenever changing oil l 2 3 4 6 CAUTION Hot oil can cause burns to Position the vehicle on a level surface Start the engine Allow it to idle for two to three minutes Stop the engine Clean the area around the drain plug Place a drain pan under the oil ae Screen iene Fitting Drain L A Weg Remove the drain plug Allow Plug V7 in the oil to drain completely skin Do not allow hot oil to contact skin ds 10 11 70 Install a new sealing washer on the drain plug The sealing sur faces on drain plug and crank case should be clean and free of burrs nicks or scratches Reinstall the drain plug Torque to 14 17 ft Ibs 19 23 Nm Disconnect the lower oil deliv Alignment Mark ery hose and remove the screen fitting from the oil tank Clean the fitting The fitting threads must be sealed with LOCTITE PST 505 or PTFE seal tape Reinstall the screen fitting and rotate the fitting clockwise a mini mum of 2 1 2 turns into the tank threads Continue to rotate the fit ting until the nipple of the fitting aligns with the mark on the tank Do not over tighten Maximum torque for the screen fitting is 25 ft Ibs 34 Nm Reattach the oil line
101. time the fluid looks dark or contaminated Coolant test strength fill Fog the Engine l 2 Support the front end of the machine so the engine is level or tilted slightly rearward Remove the spark plug Rotate the piston to BDC and pour two ounces 59 ml of engine oil into the cylinder Reinstall the spark plug Torque to specification Apply dielectric grease to the inside of the spark plug cap Reinstall the cap Turn the engine over several times Oil will be forced in and around the piston rings and ring lands coating the cylinder with a protec tive film of fresh oil Treat the fuel system with POLARIS Carbon Clean See page 109 If POLARIS fuel system additive is not used the 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 110 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 62 Battery Storage See pages 100 101 for storage and charging procedures Storage Area Covers Set the tire pressure and safely support the ATV with the tires slightly off the ground Be sure the storage area is well ventilated Cover the vehicle with a genuine POLARIS cover Do not use plastic or coated materials They do not allow enough ventilation to prevent condensa t
102. tion Using constant current Charge charger standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 None required mos from date of manufacture 75 100 12 5 12 8 volts May need slight 3 6 hours charge if no charge given check in 3 months Needs charge 5 11 hours 50 75 12 0 12 5 volts 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At least 20 hours 102 MAINTENANCE Camber and Caster The camber and caster are non adjustable Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counter clockwise to increase or decrease spring tension Accessory springs are available through your POLARIS dealer Handlebars The handlebars can be adjusted for rider preference WARNING 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 serious injury or death Follow the adjustment procedures exactly or see your POLARIS dealer for service 1 Remove the upper headlight pod 2 Loosen the four handlebar bolts 3 Adjust the handlebar to the desired height 4 Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the l
103. tlet cover or plug 93 MAINTENANCE PVT System A WARNING Failure to comply with the instructions in this warning can result in severe injury or death Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at a high speed The PVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures Always look for and remove debris inside and around the clutch and vent system when replacing the belt See your dealer as outlined in the owner s manual This PVT system is intended for use on POLARIS products only Do not install itin any other product Always make sure the PVT housing is securely in place during operation 94 MAINTENANCE PVT System 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 fly weights also increases This in turn increases the amount of pinch applied to the drive belt Similarly if the eng
104. trical failures a fuse may need replacement Locate and correct any short circuits that may have caused the blown fuse then replace the fuse Spare fuses are provided in a compartment on the top of the access door 1 Open the front box cover 2 Remove the suspect fuse from the fuse panel If the fuse is blown install a new fuse with the same amperage 3 Secure the front box cover MAINTENANCE 85 MAINTENANCE Lights Poor lighting can result in reduced visibility when driving Headlight and taillight lenses become dirty during normal operation Clean lights frequently and replace burned out lamps promptly Always make sure lights are adjusted properly for best visibility Headlight Lamp Replacement When servicing a halogen lamp don t touch the lamp with bare fingers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp 1 Remove the two screws on the lower front corners of the headlight pod Remove the screw from the rear of the pod 3 Lift the pod slightly while depressing the tabs at the rear of the pod Lift the pod cover and disconnect the speedometer harnesses from the speedometer CAUTION Hot components can cause burns to skin Allow lamps to cool before servicing 5 Unplug the headlamp from the wiring harness Be sure to pull on the connector not on the wiring 6 Turn the lamp counter clockwise to remove it 7 Apply dielectric grease to the socke
105. tructions apply only to the installa tion of a sealed battery Read all instructions before proceeding with the installation of this battery The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Never pry the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage WARNING An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher 2 Ifthe voltage is less than 12 8 volts recharge the battery at 1 2 amps or less until battery voltage is 12 8 or greater 3 When using an automatic charger refer to the charger manufac turer s instructions for recharging When using a constant current charger use the guidelines on the next page for recharging 101 MAINTENANCE Battery Battery Charging Sealed Battery Always verify battery condition before and 1 2 hours after the end of charging State of Charge Time Voltage Ac
106. ving on Slippery Surfaces 50 Driving Over Obstacles 56 Driving Procedures 48 Driving Through Water 55 Driving Uphill sessi 51 E Electromagnetic Interference 61 Engaging AWD 33 Engine Break In 42 Engine Fogging 110 Engine Idle RPM Adjustment 104 Engine Oil 68 69 Equipment Modifications 9 Etiquette Trail Riding 44 Exhaust Emission Control System 61 Eye Protection 9 F Fluid Brake 2 5 sisien cay ated 28 30 Fluid Demand Drive 74 75 Fluid Change Demand Drive 75 Foot Brake Auxiliarv 30 Footwell Removal 80 Fuel Filt r rer osr sapbim izzjotiu 31 Fuel Recommendations 31 Fuel Safety 0000 11 Fuel Tank Cap 31 Fuel Valve 31 Fuse Replacement 85 131 INDEX G Gasoline Handling 11 Gear Selector csse serit ees 32 Gloves 2s hobonb UT TES 9 H Hand Brake s siti sez 78 Handlebar Adjustment 103 Hauling Cargo 58 59 Headlight Housing Replacement 88 Headlight Lamp Replacement 86 Headlight Switch 25 Hemet 55 sire sepe rtr ettam tee 8 High Beam Adjustment 87 High Range Use 96 l Idle RPM Adjustment 104 Immersion Maintenance 92 Instrument Cluster
107. worn to 1 8 3 mm or less tp NS Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical com ponent operations All service must be performed by your authorized POLARIS dealer Wheel Removal 1 Stop the engine 2 Place the transmission in PARK 3 Lock the parking brake 4 Loosen the wheel nuts slightly WARNING Do not service axle nuts that have a cotter pin installed See your POLARIS dealer 5 Elevate the side of the vehicle by placing a suitable stand under the footrest frame 6 Remove the wheel nuts 7 Remove the wheel 81 MAINTENANCE Tires Wheel Installation 1 Place the transmission in PARK Lock the parking brake 3 Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation 4 Install the wheel nuts and finger tighten them 5 Lower the vehicle to the ground 6 Torque the wheel nuts to specification WARNING Loose nuts could cause a tire to come off during operation which could result in an accident or overturn Always ensure that all nuts are torqued to specification Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loos ened for maintenance service Nut Type Nut Torque Lug Nut Aluminum is 30 ft Ibs 41 Nm Wheels PLUS 1 4 TURN 2 Piece Flange Nut 9 27 ft Ibs 37 Nm Steel Wheels CO 82 MAI
108. y 100 hours thereafter PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and better performance Break in the clutches and belt by operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggressive acceleration and high speed operation dur ing the break in period If a belt fails always clean away all debris when replacing the belt 42 OPERATION Safe Operation Practices 1 2 10 11 12 13 14 Complete the recommended safetv training before operating this Vehicle See page 7 Do not allow anyone under 16 years of age to operate this vehicle Do not allow anyone with cognitive or physical disabilities to oper ate this vehicle Never carry a passenger on this ATV Engine exhaust fumes are poisonous Never start the engine or let it run in an enclosed area Before operating learn how to use the auxiliary brake for emer gency situations 1f service brakes become inoperable Operate this vehicle off road only Never operate the vehicle on pavement or on any public street road or highway including dirt and gravel roads Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness Clean headlights fre quently and replace burned out headlamps promptly Drive in a manner appropriate for your skills and operating condi tions Never operate at excessive spe
109. y considerably from country to country You may be required to present documentation of your move to POLARIS Industries in order to continue your warranty coverage You may also be required to obtain documentation from POLARIS Industries in order to register your vehicle in your new country You should warranty register your vehicle at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive safety information and notices regarding your vehicle 124 WARRANTY Exported Vehicles How to Get Service If Purchased From A Private Party If you purchase a POLARIS product from a private citizen to be kept and used outside ofthe country in which the vehicle was originally purchased all warranty coverage will be denied You must nonetheless warranty register your vehicle under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your vehicle Notice If your vehicle is registered outside ofthe country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ranty or service bulletin coverage of any kind other than safety bulletins Vehicles reg istered to Government officials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic war ranty

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