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1. 7 Vehicle Identification Numbers 6 Warrant ye susanne aaia seas SEA 173 175 Welcomes naa cedar eae a b 2 Wheel Installation 139 140 Wheel Removal 4 139 177 AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS 01 W N o0 0 i PROTECTIVE GEAR NEVER e Operate without proper training or instruction e Operate on public roads A collision can occur with another vehicle e Operate at speeds too fast for your skills or the conditions e Use ALCOHOL or DRUGS before or while operating this vehicle Carry Passengers ALWAYS e Avoid paved surfaces which may adversely affect handling and control e Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills and rough terrain and in turns e Wear eye protection helmet and protective apparel READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS POLARIS The Way Out Part No 9916632 Rev 02 PRINTED IN THE USA
2. 0 0 00 cece wees 135 Brakes uinna enea n nE aes 45 Brakes Front 00000 eee 46 Brakes Rea oas wes hes Mae ae 46 Break in Period 69 72 Breather Filter Sportsman 500 Xplorer 500 sia aka eeni eat 129 Camber and Caster 130 Carburetor Adjustment 4 Cycle 137 Carburetor Adjustment 2 Cycle 136 Carburetor Adjustments 145 Carrying Loads 0 75 77 Chain Adjustment 143 Choke Leveroni ise car ea tans ate oat 44 Cleaning and Storage 165 168 Cleaning The Main Filter 131 COMtTOIS gs ies a wees Th 46 60 Coolant Level 000 101 Counter Balance Lubrication 124 Counter Balance Oil Changing Procedure 55 659 sae eiieeii 125 Crossing Streams 00 00 84 Cylinder Head Torque 138 Disengaging Wheel Hubs 59 Drive Chain Adjustment 142 Engine Choke Adjustment 137 Engine Cooling System 101 103 Engine Electrical Switches 43 Engine Idle Rpm Adjustment 137 Engine Idle Rpm Adjustment 136 Engine Stop Switch 43 Features ta paiia dare techs gee dette 6 58 65 Features and Controls 43 65 Filter Change 108 116 Filter Systems 127 129 Fluid beyls 15 3 divs sew ated eneak 166 Fogging The Engine 167 Fuel Safety 0 2 0 0
3. 94 Maintenance Record 0e eee eeees 100 Cooling System acs 2c bee tae Peedi 101 PUBICAHOR siete te a ante Rea A Ate e 104 Filter Systems once cdeta gwen weeny oes magnetar eed 127 AC USUMGIIS v santia he Poe shake EE 130 EONS menehna 0 Sar n ota E axe waste Pah EA e ang 146 Spark PIHS a2 i oe eee oe ce ee Bae ene ee 153 Water Servite cst taiota bailed eae Boe eek a 154 Spark Arresto urn whine Sera ec guia EENE 155 Recoil ROUSING 26s icin ww eure Sod nee sie naw ne 157 ch Re Bete wm a A nal E 158 Bale os creel eect tee one wera line Scent ol A ong 161 Side Panel Removal 00000 eee eaes 164 Cleaning and Storage 0 eee eee 165 Trouble Shooting 0005 169 172 Warranty sienna is eked ones 173 175 VEHICLE IDENTIFICATION NUMBERS Record these numbers from your ATV in the spaces provided 1 Frame VIN found on the lower left side of the frame tube 2 Engine Serial Number Right front side of engine crankcase Remove the spare key and store in a safe place Your key can be duplicated only by obtaining a key blank from Polaris and having it cut by mating it with your existing key The vehicle frame and engine serial numbers are important for model identification when registering your vehicle obtaining insurance or whenever replacement parts are required In the event your vehicle were stolen these numbers are essential to the recovery and identification
4. 1 Mix 12 8 ounces of injection oil to four gallons or 16 ounces to 5 gallons of gasoline in a suitable gas can Fill the fuel tank as outlined on page 49 2 Fill the oil tank with Polaris injection oil 3 Drive slowly at first Select an area which is open and will give you room to familiarize yourself with vehicle operation and handling CAUTION Do not operate at full throttle or high speeds for extended periods during the first three hours of use Excessive heat can build up and cause damage to close fitted engine parts 4 Vary the throttle positions 5 Perform regular checks on fluid levels controls and all important areas on the vehicle as outlined earlier on the daily pre ride inspection checklist found on page 66 67 OPERATION Break In Period After the break in period the oil injection system provides the necessary engine lubrication without the need for pre mixed fuel CAUTION Fill the oil tank when you refuel your ATV If you don t serious engine damage could result After the first tank of pre mixed fuel has been used please verify that the oil level in the oil tank has dropped indicating that the oil pump is functioning properly If the level has not dropped see your dealer for oil pump bleeding and repeat the pre mix procedure 68 OPERATION Break In Period 4 Cycle Engines The break in period for your new Polaris ATV is defined as the first ten hours of operation or the time it takes
5. ENGINE STOPS OR LOSES POWER Spark Plug Engine Fouled Overheated Turn Fuel Air Filter Valve to Res Clogged Clean Radiator screen and Radiator Core Fuel Vent Line Kinked or liquid cooled Reverse Speed models Limiter Malfunction Plugged 172 Water in Fuel Electronic ee Engine Throttle Control xterior Malfunction Contact Your Dealer Contact Your Dealer Overuse of Choke WARRANTY LIMITED WARRANTY Polaris Industries Inc 2100 Highway 55 Medina MN 55340 gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle ATV against defects in material or workmanship Polaris also gives a one year limited warranty on the final drive chain for failure due to defects This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transferrable to another consumer during the warranty period through a Polaris dealer There is a charge of 35 00 payable to Polaris Industries Inc REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty THE PURCHASER MUST COMPLETE AN ATV SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE ATV No verificatio
6. Safe Riding Tips Turning Around On A Hill If the ATV stalls while climbing a hill never back it down the hill One maneuver which can be used when it is necessary to turn around while climbing a hill is the K turn 1 Stop and lock the parking brake while maintaining body weight uphill 2 Leave transmission in forward and shut off engine 3 Dismount on left or uphill side of ATV 4 Staying uphill of ATV turn handlebars full left while facing front of ATV 5 While holding service brake release parking brake lock and slowly allow ATV to roll around to your right until ATV is pointing across the hill or slightly downward 6 Lock the parking brake and remount ATV from the uphill side maintaining body weight uphill 7 Restart engine with transmission still in forward release parking brake and proceed slowly controlling speed with the service brake until ATV is on reasonably level ground AWARNING Avoid climbing steep hills Loss of vehicle control or overturning of the ATV could occur resulting in severe injury or death 83 RIDING Safe Riding Tips Crossing Streams Your Polaris ATV can operate through water up to maximum recommended depths reaching the footrests Before fording streams always 1 Determine water depths and current 2 Choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles if possible 4 After crossing dry the brakes by applying li
7. 250 Engines 1 Before adjusting the oil pump check engine idle RPM and carburetor adjustments which are found in the owner s manual supplement 2 Loosen throttle cable jam nut A and turn adjuster in or out until there is 1 16 1 8 16 32 cm of throttle lever travel before throttle slide starts to open See Owner s Manual Supplement 3 Place very slight pressure on the throttle lever until all freeplay is removed from throttle cable to the point where the carb slide is just starting to rise 4 Loosen locknut Turn Locknut adjuster in or out until all freeplay is removed from oil pump cable the point where the oil pump arm is just starting to move off of its stop The pump stop keeps the pump arm from rotating any farther down than the idle position so no visual Lever Arm alignment of marks is necessary Tighten the locknut Cable Adjuster Locknut 107 MAINTENANCE AND LUBRICATION Lubrication Oil Pump Bleeding Procedure 1 Fill the oil reservoir with Polaris injector oil 2 Loosening the bleeder screw is only necessary when the oil supply line has been disconnected from the pump or the oil reservoir and supply line have been completely run out of oil In these cases loosen the pump bleed screw one full turn Allow oil to flow from the bleed screw for five to ten seconds Tighten bleed screw CAUTION Never run the engine with the bleed screw loose Loss of oil will cause serio
8. battery fluid level often The fluid Maintain level should be kept between the between upper and lower level marks nee and ower level To refill use only distilled water marks Tap water contains minerals which are harmful to a battery 161 MAINTENANCE AND LUBRICATION Battery Battery Removal 1 Disconnect hold down straps holding the electrical box and battery in position and remove battery cover Remove the battery vent tube from the battery Disconnect the black negative battery cable first Disconnect the red positive battery cable next Lift the battery out of the ATV being careful not to tip it sideways and spill electrolyte MEN 4 CAUTION If electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the ATV Battery Installation and Connections AWARNING To avoid the possibility of explosion always connect battery cables in the order specified Red positive cable first black negative cable last An exploding battery can cause serious injury or death Battery terminals and connections should be kept free of corrosion If cleaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean rags Coat the terminals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution
9. eee ee 49 Fuel Stabilizer 000 166 Fuel System 0 00 00 49 51 Fuel Valves try 63 tenes ae eevee td 49 Gearcase Oil Changing Procedure 122 176 Handlebar Adjustment 133 Headlight Adjustment 147 150 Headlight Lamp Replacement 146 149 Indicator Lamp Replacement 152 Indicator Lights 0 60 Key Safety Issues 0 00 8 11 Light Switches 00 00 55 Lights iiine aart pot Gye ors d 146 152 Lubricant 2cycle 104 Lubrication 00 104 126 Lubrication Recommendations 94 99 Main Switch 0000 43 Maintenance and Lubrication 88 168 Maintenance Record 100 Making Turns 00 00 78 Manual Shift 00 53 Noise Control System 75 Oil Change 108 116 Oil Change Engine 4 Strokes 111 Oil Filter Change 111 Oil Pump Adjustment 106 107 Oil Pump Bleeding 108 Oil System 4 49 51 126 Operation ers sie Bie te else eis ern eo 66 74 Operator Safety 000 22 42 Override Switch 00 43 Parking On An Incline 87 Periodic Maintenance Schedule 91 96 Pre Operation Inspection 76 Pre Ride Inspection 66 Premium 4 Synthetic Lubricant 105 PVT System 00
10. require backing downhill ALL LOADS MUST BE SECURED BEFORE MOVING VEHICLE Unsecured loads can create unstable operating conditions which could result in loss of control of the ve hicle 73 OPERATION Carrying Loads 74 LOADS MUST BE CARRIED AS LOW ON THE RACKS AS POSSIBLE Carrying loads high on the racks raises the center of gravity of the vehicle and creates a less stable oper ating condition When cargo loads are carried high on the racks the weight of the loads must be reduced to maintain stable operating conditions OPERATE ONLY WITH STABLE AND SAFELY AR RANGED LOADS When handling off centered loads which cannot be centered securely fasten load and operate with ex tra caution Always attach the tow load to the hitch point designated for your ATV EXTREME CAUTION MUST BE USED when operating with loads extending over the rack sides Stability and ma neuverability may be adversely affected causing the machine to overturn DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the front rack DO NOT TRAVEL FASTER THAN THE REC OMMENDED SPEEDS Vehicle should never exceed 10 mph 16 kph while towing a load on a level grass surface Vehicle speed should never exceed 5 mph 8 kph when tow ing loads in rough terrain while cornering or while ascend ing or descending a hill NOISE EMISSION CONTROL SYSTEM REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED U S Federal law prohibits the following acts
11. start the engine by engaging the starter Brake Start This model also has a brake start feature that can be used when it is difficult to find neutral To activate pull on the LH brake lever and engage the starter 1 1143 la LLALA ener R ANANN Ce To downshift depress the R pedal one full stroke 54321 53 CONTROLS AND FEATURES Controls Shift Pedal The gear shift pedal is above the left floorboard One full stroke of the pedal shifts the transmission to the next higher or lower gear in the shifting sequence The pedal automatically returns to the horizontal position when released The Xpedition has five forward gears 1 2 3 4 and 5 To upshift to a higher gear put the toe of your boot under the gear shift pedal and raise the pedal one full stroke To downshift step on the gear shift pedal and depress the pedal one full stroke Shifting Gears Start the engine and let it warm up follow this procedure 1 With the transmission in neutral hold the brake lever 2 With the throttle closed raise the gear shift pedal one full stroke to shift into first gear 3 Release the brake lever and increase engine speed by gradually opening the throttle 4 When speed increases release the throttle and shift to 2nd gear by raising the gear shift pedal one full stroke 5 Repeat sequence 4 to progressively upshift to 3rd 4th and 5th top gear 6 To downshift reverse sequence 4 Remember to relea
12. NOTE Rider weight must be included on the seat Loosen pivot bolt and adjust beam to desired position Tighten nut and bolt Torque to 60 in lbs AWARNING Indicates a potential hazard that could result in serious injury or death 147 MAINTENANCE AND LUBRICATION Lights Adjustment Replacement Headlight Lamp Replacement Trail Blazer 1 Remove front cover and unplug the light harness 2 Remove rubber cap from back of headlight to reveal retention screw 3 Remove small phillips head screw and carefully remove bulb from housing 4 Insert new bulb into housing and tighten retention screw install rubber cap 5 Reconnect light harness 6 Install cover to machine 7 Properly adjust headlight aim Headlight Adjustment 1 Place the vehicle on a level surface with the headlight approximately 25 7 6 m from a wall 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 3 Start the engine and turn on headlight 4 Observe headlight aim The most intense part of the headlight beam should be aimed 8 20 3 cm below the mark placed on the wall in step 2 NOTE Rider weight must be included on the seat 5 Adjust beam to desired position by turning adjustment screws 1 148 in headlight cover Turning right screw clockwise moves the intense spot of light up to the left Turning the left screw clockwise moves intense spot
13. Rear 3 8 20 Ft Lbs Rear 1 2 50 Ft Lbs NOTE All nuts that have a cotter pin installed must be serviced by an authorized Polaris Dealer 140 MAINTENANCE AND LUBRICATION Adjustments Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations Service work must be performed by your authorized Polaris dealer Tire Inspection When replacing a tire always use original equipment size and type Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 cm 1 or less Please refer to your Owner s Manual Supplement for tire specifications 141 MAINTENANCE AND LUBRICATION Adjustments Drive Chain Inspection and Adjustment Polaris ATV drive chains are equipped with O ring sealed permanently greased pins and rollers However it is still necessary to lubricate the outer surfaces of the roller CAUTION Never wash the chain with a high pressure washer or gasoline Damage to the O rings will result causing premature wear and drive chain failure Always inspect the drive chain prior to operating the vehicle checking for damaged or missing O rings rollers and correct slack adjustment Maintain the stone guard to rear sprocket clearance at 1 8 3 cm Regularly lubricate the drive chain with SAE 80 90 lube or an approved O ring chain spray lube 142 MAINTENANCE AND LUBRICATION Adjustments Rear Drive C
14. Run engine for two to three minutes until warm Shut engine off Place a drain pan beneath the plug and remove it Allow oil to drain completely Install a new sealing washer on oil drain plug NOTE The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs nicks or scratches Reinstall drain plug and torque to 14 17 ft Ibs 1 93 2 35 kg m Disconnect the lower oil delivery hose Remove the fitting C from the oil tank Clean the fitting screen Reinstall the fitting screen torquing to 14 17 ft lbs Reattach oil line If banjo fitting D is used torque to 14 17 ft Ibs If hose clamp E is used tighten to 25 in Ibs Place shop towels beneath oil filter Using an oil filter wrench turn filter counterclockwise to remove 10 Using a clean dry cloth clean filter sealing surface on crankcase 109 MAINTENANCE AND LUBRICATION Lubrication Oil Filter and Change Cont 4 Stroke models with an external oil tank 11 Lubricate O Ring on new filter with a film of new engine oil Check to make sure the O Ring is in good condition Also make sure the O ring from the old filter is not still on the engine 12 Install new filter and tighten by hand 1 2 to 3 4 turn after gasket contact 13 Approximately 1 cup of engine oil will remain in the crankcase To drain remove drain plug found on lower right side of crankcase NOTE The sealing surfaces on the drain plug and crankcase should
15. SAFETY Safety Decals and Locations AWARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death NEVER operate this ATV if you are under age 16 7078253 4 WARNING Never operate this ATV on HILLS steeper than 25 degrees 25 To prevent flipover on hilly terrain when going up or down use throttle and brakes gradually REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent flipover avoid sudden braking or sharp turns Use OVERRIDE for reverse speed limiter with caution To prevent loss of control never activate override button with open throttle PARKING BRAKE may relax when used for more than 5 minutes When parking on grades leave shift in forward 7079085 15 SAFETY Safety Decals and Locations 16 SAFETY Safety Decals and Locations EVAR NING NEVER ride as a passenge Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH NO PASSENGER PASSAGERS INTERDITS on rear of seat A WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE PSI FRONT REAR ___ MAXIMUM WEIGHT CAPACITY Gross Vehicle Weight INCLUDING MACHINE DRIVER AND CARGO IS LBS Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your
16. an enclosed area The exhaust con tains poisonous carbon monoxide gas Do not go under the machine while it is inclined Keep combustible materials away from exhaust system Fire may result Spark Arrestor The exhaust pipe must be periodically purged of accumulated carbon as follows 1 Remove the clean out plugs 1 located on the bottom of the muffler as shown above 2 Place the transmission in neutral and start the engine Purge accumulated carbon from the system by momentarily revving the engine several times 3 Ifsome carbon is expelled cover the exhaust outlet and rap on the pipe around the clean out plugs while revving the engine several more times 155 MAINTENANCE AND LUBRICATION Spark Arrestor cont 4 If particles are still suspected to be in the muffler back the machine onto an incline so the rear of the machine is one foot higher than the front Set the parking brake and block the wheels Make sure the machine is in neutral and repeat steps 2 and 3 5 If particles are still suspected to be in the muffler drive the machine onto the incline so the front of the machine is one foot higher than the rear Set the parking brake and block the wheels Make sure the machine is in neutral and repeat steps 2 and 3 6 Repeat steps 2 through 5 until no more i particles are expelled Q when the engine is Bp revved 1 7 Stop the engine and allow the
17. arrestor to cool 8 Reinstall the arrestor plugs 156 MAINTENANCE AND LUBRICATION Recoil Housing Drain the recoil housing after operating the ATV in very wet conditions This should also be done before storing the ATV The drain screw is located at the bottom of the recoil housing Using a wrench remove the screw Reinstall screw once housing has been drained Water will enter the recoil housing if the starter handle is disengaged from the rope guide when under water After travelling in wet areas the recoil housing and starter should always be drained completely by removing the recoil Do not open the crankcase drain unless the engine has ingested water On 4 cycle engines some engine oil will be lost if crankcase drain is opened On the Trail Blazer the recoil handle must be behind the heat shield for it to seal properly If it is not sealed properly water may enter the recoil housing and damage components A 250 and 400 Engines B 4 Cycle Engines 5 Crankcase Drain 6 Starter Pinion Drain 7 Recoil Drain above front prop shaft on shaft drive models Counter Balance Drain 400s 157 MAINTENANCE AND LUBRICATION PVT System AWARNING The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to insure the safety of this product However as t
18. disengaging technique before proceeding Failure to disengage front hubs as directed above could result in severe injury or death NOTE If the hubs remain engaged after following these instructions return the ATV to your dealer for service Switches The light switch is located on the left hand handlebar In addition to turning the lights on and off it also switches the lights from Hi to Lo on models equipped with Hi Lo beams NOTE The lights will not work unless the key is in the on position and shut off switch is in the run position 59 CONTROLS AND FEATURES Features Indicator Lights Each Polaris ATV has indicator lights The configuration of these lights differs with individual models and not every model is equipped with all the lights The information in your Owner s Manual Supplement and in the information on this page will help you identify the lights on your machine and their function 1 Transmission Neutral Green 2 Transmission Reverse Yellow 3 Oil Warning Red On 2 cycle models this light indicates a low oil level 4 High Temp Red Will light only if engine overheats 5 All Wheel Drive Red located on the throttle control Refer to page 58 6 High Beam Indicator Blue located on the LH switch on models equipped with Hi Lo beam lights With engine running verify function of indicator lights each time ATV is used NOTE The taillight is on whenever the main switch key is in the on
19. in soapy water rinse and let dry Re install pre filter over main filter Replace main filter if required Filter Installation Procedure 1 2 3 Check condition of airbox and replace if necessary Replace filter over carburetor boot Make certain filter is fully seated in the air box Tighten clamp Do not overtighten or filter damage may occur Check cover gasket and replace if required Be certain the cover is seated properly and snap the clips on to the cover Reinstall ATV seat 127 MAINTENANCE AND LUBRICATION Filter Systems Cleaning the Main Filter NOTE It is advisable to replace the filter when it is dirty However in an emergency it is permissible to clean the main filter if you observe the following practices 1 Never immerse the filter in water since dirt can be transferred to the clean air side of the filter 2 If compressed air is used never exceed a pressure of 40 PSI Always use a dispersion type nozzle to prevent filter damage and clean from the inside to the outside NOTE Replace the air filter every 50 hours and possibly more often in very dirty conditions Air Filter Service 4 Cycle 1 Remove seat 2 Release clips and remove cover 3 Loosen clamp and remove filter 4 Remove fabric type pre filter 1 from main filter 2 Wash pre filter in soapy water and dry it 5 Reinstall pre filter over main filter Replace main filter as required 6 Reinstall filter into air box
20. incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars resulting in loss of control and possible serious personal injury or death Handlebar Adjustment Your ATV has handlebars which can be adjusted for your personal fit 1 Locate handlebar bolts On models with a headlight pod it will be necessary to remove the upper headlight pod On other models remove the handlebar cover 2 Loosen the four bolts 3 Adjust handlebar to desired height Be sure handlebars do not hit gas tank or any other part of machine when turned fully to left or right 4 Torque handlebar adjuster block bolts to 10 to 12 ft Ibs NOTE Tighten bolts so there is an equal gap at the front and rear of the handlebar block Improper gap will result in improper fit of upper pod 133 MAINTENANCE AND LUBRICATION Adjustments Front Brake AWARNING Once a bottle of brake fluid is opened use what is necessary and discard the rest Do not store or use a partial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air This causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of serious injury The front brakes are hydraulic disc brakes which are activated by the brake lever being moved toward the handlebar These brakes are self adjusting and require no adjustment Th
21. minor maintenance Major repairs are covered in the Polaris Service Manual and should be performed by a Factory Certified MSD Master Service Dealer Technician Your Polaris dealer knows your vehicle best and is interested in your complete satisfaction Return to your dealership for all of your service needs during and after the warranty period Polaris also takes great pride in our PAA Parts Apparel and Accessories which are available on our online store www purepolaris com Have your accessories and clothing delivered right to your door Polaris and Polaris The Way Out are registered trademarks of Polaris Industries Inc Copyright 2001 Polaris Industries Inc All Rights Reserved Printed in the U S A ATTENTION This is an ADULT VEHICLE ONLY not a toy Operation is prohibited for anyone under 16 years of age READ AND UNDERSTAND WARNINGS AND OWNER S MANUAL BEFORE OPERATION A KNOW YOUR VEHICLE BEFORE YOU BEGIN RIDING Read this manual thoroughly referring to the various areas which are being discussed on your machine Operating this vehicle carries with it responsibilities for your personal safety the safety of others and the protection of our environment A SAFETY TRAINING When you purchased this vehicle your dealer offered a hands on safety training course covering all aspects of ATV safety In addition you were provided with certain printed material which instructs you on safe operating procedures You sh
22. of light up to the right Turning the bottom screw clockwise adjusts the light upwards MAINTENANCE AND LUBRICATION Lights Adjustment Replacement gt DO A T Headlight Lamp Replacement Gen IV Es PR Snap pins into tabs Position NS f k Slip O Ring knob in J over pin slot and secure in locking Adjustment Route indicator Knob Stop harness over handlebar tabs Using a small flat blade screwdriver push in on the lock tab through the two small openings at the front of the headlight pod Lift the pod lightly while depressing the tabs Remove the screw in the back of the headlight pod Lift pod cover up Disconnect speedometer harnesses from speedometer Unplug indicator light harness and remove pod cover Unplug headlamp from wiring harness Remove boot and locking collar from back of lamp housing Grasp base of lamp and lift it out Reverse previous steps to replace lamp and reassemble pod Make sure tab on lamp locates properly in housing 149 MAINTENANCE AND LUBRICATION Lights Adjustment Replacement High Beam Headlight Adjustment Gen IV The headlight beam can be adjusted to any position desired by turning the adjusting knob located on the bottom right side of the headlight pod 1 Place the vehicle on a level surface with the headlight approximately 25 7 6 m from a wall 2 Measure the distance from the floor to the center of the headlight and make a
23. or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW INCLUDE BUT ARE NOT LIMITED TO THE FOLLOWING 1 Removal or alteration or the puncturing of the muffler or any engine component which conducts removal of engine exhaust gases 2 Removal or alteration or the puncturing of any part of the engine air induction system 3 Replacement of any vehicle parts with parts not in compliance with federal regulations 4 Lack of proper maintenance 4 CAUTION Remember exhaust system components are very hot dur ing and after use of ATV Serious burns can result if hot components are touched e Do not touch exhaust system components Serious burns can re sult e Be especially careful when traveling through tall grass The poten tial for fire exists USFS Approved Spark Arrestor Most Polaris ATVs have mufflers that were tested and approved in accordance with the USFS Forest Service Standard 5100 1A For specific information on your model see the Owner s Manual Specification Su
24. risk of losing control Loads should be centered carried as low as possible and firmly secured to the racks with dual racks load distribution 1 3 front 2 3 rear is best For stability on rough or hilly terrain reduce speed and cargo Do not block headlight Be careful if load extends over the side of the rack Read Owner s Manual for more detailed loading information Refer to your Owner s Manual Supplement for your vehicle s specifications 17 SAFETY Safety Decals and Locations 7 Under Seat ATTENTION e Specific carburetor jetting e Operation of this and adjustments are vehicle without the required depending on temperature filter element will severely and altitude See your Owner s Manual damage the engine Factory setting e Clean air filter often more 40 to 80 F at 0 3000 feet 5 to 27 frequent cleaning required i iti C at 0 900 meters in dusty conditions 7079901 A 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 injury or death NO STEP sare 18 SAFETY Safety Decals and Locations A 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 Maximum Rack Loads Front
25. side of the vehicle directly above and forward of the engine recoil starter The transmission selector lever has three or four positions high forward reverse neutral and low forward or forward reverse and neutral Check your Owner s Manual Supplement for specification NOTE To extend belt life use low forward gear in heavy pulling situations and in situations where you are operating below 7 miles per hour for extended periods of time CAUTION To change gears stop the vehicle and with the engine idling move the lever to the desired gear Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage Always place the transmission in gear with the parking brake locked whenever the vehicle is left unattended Maintaining shift linkage adjustment is important to assure proper transmission function Should you experience any shifting problem see your dealer 52 CONTROLS AND FEATURES Controls Manual Shift The engine can only be started with the Gear Shift Pedal transmission in neutral Turn the key to on and ensure the stop switch is in the run position The neutral indicator light should be on If it is not shift the foot pedal down or up and down if in Reverse to find neutral Refer to the ear shift pedal To shift to a higher gear i tat de a thi raise the pedal one full moar gt stroke page Once the vehicle is in neutral
26. the tank and carburetor Turn the fuel valve to OFF and drain the carburetor bowl completely Oil And Filter Change 4 Strokes Warm the engine and change oil and filter Air Filter Air Box Inspect and clean or replace the pre cleaner and air filter Clean the air box and drain the sediment tube Breather Filter s On 4 Strokes inspect and clean or replace the breather filter s Inspect All Fluid Levels Inspect the following fluid levels and change if necessary engine counter balance 2 strokes front gear case shaft drive models transmission front hubs AWD models brake fluid change every two years or as required if fluid looks dark or contaminated Drain Recoil Housing Remove drain plug from recoil housing and drain any moisture present 166 MAINTENANCE AND LUBRICATION Cleaning and Storage Fog The Engine 2 Strokes Polaris Fogging Oil PN 2870791 follow directions on the can 4 Strokes Remove the spark plug and add 2 3 tablespoons of Premium 4 Synthetic 0W40 engine oil To access the plug hole use a section of clear 1 4 hose and a small plastic squeeze bottle filled with the pre measured amount of oil Note Do this carefully If you miss the plug hole oil will drain from the spark plug cavity out the hole at the front of the cylinder head and appear to be an oil leak Install the spark plug and pull the engine over slowly with the recoil starter Oil will be forced in and around the p
27. to use the first two tanks full of gasoline No single action on your part is as important as a proper break in period Careful treatment of a new engine will result in more efficient performance and longer life for the engine Perform the following procedures carefully CAUTION Use only Polaris Premium 4 All Season synthetic oil or API certified SH oil Never substitute or mix oil brands Serious engine damage and voiding of warranty can result Do not operate at full throttle or high speeds for extended periods during the first three hours of use Excessive heat can build up and cause damage to close fitted engine parts 1 Fill fuel tank with either unleaded or ADD 8 OZ NORMAL FULL leaded fuel which has a minimum pump Maintain Oil Level In Normal Range octane number of 87 R M 2 2 Check oil reservoir level indicated on dipstick Add oil if necessary 3 Drive slowly at first Select an area which is open and will give you room to familiarize yourself with vehicle operation and handling 4 Vary the throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and all important areas on the vehicle as outlined earlier on the daily pre ride inspection checklist found on page 66 6 Pull only light loads 7 Break in oil and filter Change at 20 hours or 200 miles ee 69 OPERATION Starting the Engine Procedure for Starting a Cold Engine AWARNING Ne
28. toe alignment is 1 8 to 1 4 3 to 6 cm toe out If you discover improper adjustment have your dealer correct it 1 Set the handlebars in a straight ahead position and hold them in this position Q gf G asaS Medar GP PEQLOT Calg Fa QN OS ee Sry g 130 MAINTENANCE AND LUBRICATION Adjustments Toe Alignment cont 2 3 Place stands in front of the machine perpendicular to the rear tires Tie an elastic string around the stands making sure string just touches side surface of the rear tires on each side of machine and goes around the stands in front of the machine Measure from string to rim at front and rear of front rim Rear rim measurement should be 1 16 1 8 2 to 3 cm more than front rim measurement If this measurement needs to be adjusted contact your dealer for service AWARNING Indicates a potential hazard that could result in serious injury or death 131 MAINTENANCE AND LUBRICATION Adjustments Rear Spring Adjustment The rear shock absorber spring is adjusted by rotating the adjuster in the direction required to increase or decrease spring tension NOTE Accessory springs are available through your Polaris dealer Rear Spring Adjustment Rear Spring Adjustment 132 MAINTENANCE AND LUBRICATION Adjustments AWARNING Improper adjustment of the handlebars or
29. 1 Normal The insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service NOTE The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetion adjustments 2 Wet Fouled The insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes are excessive oil use of non recommended injection oil improper use of the choke or incorrect carburetion adjustments Spark Plug Removal and Replacement AWARNING Never attempt to remove a spark plug while the engine is warm The exhaust system or engine could burn you causing severe injury The spark plug is removed by using the special wrench provided in the tool pouch Remove the spark plug cap and then the spark plug by rotating counterclockwise Reverse the procedure for spark plug installation Torque to 17 ft Ibs Never deviate from the recommended spark plug as engine damage can occur 153 MAINTENANCE AND LUBRICATION Water Service CAUTION If your ATV becomes immersed take it to your dealer before starting the engine Major engine damage can result if the machine is not thoroughly inspected If it is impossible to take it to a dealer before starti
30. 158 160 Rear Spring Adjustment 132 Recoil Housing 157 166 Recoil Starter 000 57 Reyers rent Gtoladtaass ArT EE CANTA 55 Riding a preso ngis Higa 8 eas siaa Ee 76 87 Riding On Slippery Surfaces 79 Safe Riding Gear 0 21 Salet ADEA ie ar AAE EE AEAN NAi 8 42 Safety Decals and Locations 12 20 Safety Warning and Operation Decals 13 ShiftPedal siie Sens wees eee gee 54 SHUDE aena ae hele E tote Tete 54 56 Side Panel Removal 164 Sidehilling 00000 81 Spark Arrestor 155 156 Spark PLUGS jess ge octal Ae gw 153 Starting The Engine 70 71 Starting a Cold Engine 70 Steering Inspection 130 Storage Tips s renidi iade D ii 166 Table Of Contents 4 5 Taillight Brakelight Lamp Replacement 152 Throttle Cable Adjustment 108 Throttle Lever sez cuoio hpna 44 Tire Inspection 00 141 Toe Alignment 130 131 Torque Specifications 140 Trail Obstacles 00 85 Transmission Lubrication 117 119 Transmission Oil Changing PLOCEMUTE edonor ela eeed as 118 121 Transporting 000 168 Traveling Downhill 82 Traveling Uphill 0 80 INDEX Troubleshooting 169 172 Turning Around Ona Hill 83 Understanding Warnings
31. 542 NOTE Your machine will not have all the decals depicted on this page The decals found on your machine will depend on the model you own 20 SAFETY Safe Riding Gear Always wear clothing suited to the type of riding you are doing ATV riding requires special protective clothing which will make you feel more comfortable and reduce chances of injury 1 Helmet Your helmet is the most important piece of protective gear for safe riding A helmet can prevent a severe head injury Select an approved helmet which meets or exceeds your state s safety standards and bears either the Department of Transportation DOT label the American National Standards Institute label ANSI 290 1 or the Snell Memorial Foundation label 2 Eye Protection Do not depend on sunglasses for proper eye protection A pair of goggles or helmet face shield offer the best protection for your eyes They should be kept clean and be of shatterproof design bearing the markings z2 1 or VESC 8 3 Gloves Off road style gloves with knuckle pads are the best for comfort and protection 4 Boots The best footwear is a pair of strong over the calf type boots with heels such as moto cross boots 5 Clothing To protect your body long sleeves and pants should always be worn Riding pants with kneepads a jersey and shoulder pads provide the best protection 21 SAFETY Operator Safety 22 4 WARNING POTENTIAL HAZARD Operating t
32. 90 Ibs Rear 180 Lbs 7070021 19 SAFETY Safety Decals and Locations MANUFACTURED 4 WARNING BY POLARIS IND Pushing reverse override button OVERRIDE SWITCH may cause sudden in creases in pow er and traction if too much throttle is ap Reverse Speed is limited yes THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND Reverse override is IS NOT INTENDED FOR USE ON PUBLIC ROADS controlled by the plied Loss of override switch control or for ward flipover may result es pecially in AWD See Own er s Manual CE VEHICULE EST UN VEHICULE TOUT TERRAIN QUI N EST PAS DESTIN A ETRE UTILIS SUR See your Owner s LES CHEMINS PUBLICS Manual 7079906 PRINTED IN U S A 7077185 2WD Models 7079604 Chain Freeplay Is Important Adjust Freeplay to 3 16 3 8 AWD Models DO NOT Overtension See Owner s Manual Torque Nut on Eccentric Bolts To 30 Ft Lbs For models without a hitch ALL WHEEL To 60 Ft Lbs For models with DRIVE ahiteh 7078572 SWITCH TRAILER MAX POIDS MAX DE Do not push switch to WEIGHT 850 LBS REMORQUE 386 KG engage AWD if the rear wheels are spinning HITCH MAX VERTICAL POIDS MAX This may cause severe WEIGHT 30 LBS VERTICAL D ATTACHE drive shaft and clutch 14 KG damage 7072533 See your Owner s Manual TRAILER MAX WEIGHT 1225 LBS 556 KG ON LEVEL GROUND 7079780 850 LBS 368 KG UP TO 15 GRADE HITCH MAX VERTICAL WEIGHT 35 LBS 16KG 7077
33. D LUBRICATION Adjustments Carburetor Engine Idle RPM Adjustment 4 cycle Engines If the engine idle speed is not satisfactory and all other conditions are favorable the carburetor can be adjusted as follows 1 Warm up the engine by running the vehicle approximately five minutes Place the transmission in gear with the parking brake applied Adjust the carburetor idle screw A in or out until the desired idle RPM is reached Turning the screw in clockwise will raise RPM Turning the screw out counterclockwise will lower RPM Throttle Cable Free Play Adjustment Throttle cable free play is adjusted at the handlebar 1 2 Slide the boots B off inline cable adjuster sleeve C Loosen adjuster locknut D Turn adjuster until 1 16 to 1 8 freeplay is achieved at thumb lever NOTE While adjusting freeplay it is important you flip the throttle lever back and forth Tighten locknut and slide boots over cable adjuster until they touch at the mid point of adjuster 137 MAINTENANCE AND LUBRICATION Adjustments Cylinder Head Cylinder Base Fastener Torque 2 Cycle Models Have your dealer check the ATV cylinder head and cylinder base fasteners for proper torque at the first service or after 25 hours 138 MAINTENANCE AND LUBRICATION Adjustments AWARNING Operating your ATV with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehi
34. GP PGLARIS 2002 ATW Universal fet a Z WARNING The engine exhaust from this product contains chemicals known to cause cancer birth de fects or other reproductive harm Acard containing important safey 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 as sistance AWARNING Indicates a potential hazard that could result in serious injury or death We ve created a web site just for YOU e Technical tips e New product introductions e Event schedules e Parts and Service Manual information e Exciting details about The Way Out Check it out www polarisindustries com owner POLARIS The Way Out WELCOME Thank you for choosing Polaris and welcome to our world wide family of Polaris enthusiasts Polaris proudly produces an exciting line of recreational products including snowmobiles all terrain vehicles personal watercraft utility vehicles and Victory motorcycles We believe Polaris sets the standard of excellence for all recreational vehicles manufactured in the world today Many years of experience in engineering design and development have gone into making your Polaris vehicle the finest machine we ve ever produced Follow the instructions and recommendations in this Owner s Manual for safe and enjoyable operation of your vehicle Your Owner s Manual contains instructions for
35. HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking Always follow the instructions in the Owner s Manual for carrying cargo or pulling a trailer See pages 72 through 74 4 WARNING POTENTIAL HAZARD Riding on frozen lakes and rivers WHAT CAN HAPPEN Severe injury or death can result if the ATV and or the operator break through the ice HOW TO AVOID THE HAZARD Never ride your ATV on a frozen body of water before you are sure the ice is thick enough and sound enough to support the machine and its operator as well as the force that is created by a moving vehicle SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or a collision Could cause the ATV to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Use extreme caution when riding over large obstacles such as large rocks or fallen trees If you cannot avoid obstacles always follow proper procedures as described in the Owner s Manual 4 WARNING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN You may lose control of the ATV You may also regain traction unexpectedly which may cause the ATV to overturn HOW TO AVOID THE HAZARD On slippery surfaces such as ic
36. Replace sealing washer on drain plug NOTE The sealing surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches Reinstall drain plug and torque to 14 ft Ibs 1 9 kgm Place shop towels beneath oil filter Using an oil filter wrench turn filter counterclockwise to remove Using a clean dry cloth clean filter sealing surface on crankcase Lubricate O ring on new filter with a film of engine oil Check to make sure the O ring is in good condition Install new filter and turn by hand until filter gasket contacts the sealing surface then turn an additional 1 2 turn Remove dipstick and fill sump with 4 5 quarts 4 25L of Polaris Premium 4 synthetic oil 113 MAINTENANCE AND LUBRICATION Lubrication Oil Filter and Change Cont Xpedition 325 13 Shift machine into neutral and set parking brake 14 Start the engine and let it idle for one to two minutes Stop the engine and inspect for leaks 15 Re check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick 16 Dispose of used filter and oil properly NOTE Drain Plug Torque 14 ft lbs 19 Nm Oil Filter Torque Turn by hand until filter gasket contacts the sealing surface then turn an additional 1 2 turn 114 MAINTENANCE AND LUBRICATION Lubrication Oil Filter and Change Xpedition 425 1 2 Place vehicle on a level surface Oil Drain Run
37. Taillight Brakelight Lamp Replacement If the taillight brakelight does not work the lamp may need to be replaced 1 Remove the taillight lense cover mounting screws Remove the lense cover and gasket and set aside for reassembly 2 Remove lamp A and replace it with recommended lamp 3 Test the taillight brakelight to see that it s working 4 Reinstall the gasket and lens cover B removed in step 1 Indicator Lamp Replacement Style 1 Remove the upper headlight pod Gen 4 or the front cover Gen 2 to access the back of the indicator panel 2 Using a small straight blade screwdriver turn the base of the bad bulb 1 4 turn counter clockwise 3 Use a needle nose plier or similar tool to pull the lamp out of the indicator panel housing 4 Insert the new bulb and seat it by turning it 1 4 turn clockwise 5 Reassemble pod or front cover Indicator Lamp Replace ment Style Il 1 Remove mounting panel as required 2 Unplug light from harness depress locking tabs C and remove from pod 3 Install new light and reassemble panel 152 MAINTENANCE AND LUBRICATION Spark Plugs Check your owner s manual supplement for recommended spark plug and gap The spark plug and its condition is indicative of engine operation The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds Immediately check the spark plug for correct color
38. all dipstick NOTE Recommended Oil Level 2 1 Counter Balance Oil 2 Changing Procedure 1 Remove skid plate 2 Remove counter balance drain plug Catch used oil and discard of properly 3 Clean and reinstall drain plug 4 Add 10W30 oil to full mark on dipstick Capacity after draining is approximately 70 75 cc 2 3 2 5 0z 5 Reinstall dipstick and check for leaks 125 MAINTENANCE AND LUBRICATION Lubrication Oil System The oil tank is located on the left side of the vehicle or on the engine depending on the model To check the oil 1 Set machine on a level surface 2 Start the engine and let it idle for 20 30 seconds ADD 8 OZ NORMAL pam 3 Stop the engine remove dipstick and Maintain Oil Level In Normal Range wipe dry with a clean cloth 4 Screw in the dipstick completely remove it and read the oil level NOTE The dipstick must be screwed in to keep the angle and depth of stick consistent 5 Remove dipstick and check to see that the oil level is between the full and add marks Add oil as indicated by the level on the dipstick Do not overfill 126 MAINTENANCE AND LUBRICATION Filter Systems Air Cleaner 2 Cycle Engines Filter Removal and Service Procedure 1 2 3 4 gt 6 Remove the ATV seat Unsnap the clips holding the cover assembly to the air box Loosen clamp securing the filter and remove the filter Remove the foam pre filter from the main filter Wash pre filter
39. ample when operating at a ground speed of 3 MPH in low range the engine speed would be around 3000 RPM This is well above the engagement speed of 1200 1400 RPM However in high range at 3 MPH the engine would be running at only 1500 RPM Whenever operating this close to the engagement speed the engine may be running at a speed which is too low to provide adequate pinch needed to prevent belt slip This belt slip is responsible for creating the excessive heat that destroys belts and causes outer clutch covers to fail By switching to low range while operating at low ground speeds the air temperature in the clutch cover is reduced by almost 160 degrees Reducing the temperature inside the clutch cover extends the life of the PVT components belt cover etc NOTE Models without alow range should avoid heavy pulling and extended low speed operation PVT Drying There may be some instances when water is accidently ingested into the PVT system Use the following instructions to dry it out before operating First remove the drainplug and allow the water to drain Replace the drain plug Start the engine and shift the transmission into neutral Apply varrying throttle for 10 to 15 seconds This will expel the moisture and air dry the belt and clutches Allow the engine RPM to settle to idle speed and shift the transmission to the lowest available range and test for belt slippage If the belt slips repeat the process Take the vehic
40. and tighten clamp Do not over tighten clamp or filter damage may occur 128 MAINTENANCE AND LUBRICATION Filter Systems CAUTION Operation of your ATV without a breather filter can cause engine damage Breather Filter and Hose 4 Cycle Engines With Dry Sump 1 3 4 Remove the clamps and pull the filter 1 out of the hoses NOTE It will not be necessary to remove the lower hose from the engine Inspect filter for debris Blow through gently in direction of arrow on filter to check for clogging Replace as needed Check hoses for cracks deterioration abrasion or leaks Replace as needed Reinstall filter and clamps with arrow pointing toward engine Refer to your owner s manual supplement to determine if your machine has a dry sump 129 MAINTENANCE AND LUBRICATION Adjustments Steering Inspection The steering assembly of the machine should be checked periodically for loose nuts and bolts If loose nuts and bolts are found have your dealer tighten them before riding your vehicle Camber and Caster The camber and caster are non adjustable AWARNING If you determine your machine needs the tie rod adjusted for toe alignment contact your dealer for service Steering is a vital part of your machine that if adjusted wrong could lead to severe injury or death Toe Alignment You can check the toe alignment of the vehicle using the following method The recommended
41. arting the engine and allowing it to warm up shift the transmission into gear 3 Check your surroundings and determine your path of travel 4 Release the parking brake 5 Slowly depress the throttle with your right thumb and begin driving Vehicle speed is controlled by the amount of throttle opening 6 Drive slowly practice maneuvering and using the throttle and brakes on level surfaces AWARNING Indicates a potential hazard that could result in serious injury or death 77 RIDING Safe Riding Tips Making Turns Practice making turns at slow speeds Polaris ATVs are equipped with a solid rear axle which drives both rear wheels equally at all times This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly To turn steer in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest This technique alters the balance of traction between the rear wheels allowing the turn to be made smoothly The same leaning technique should be used for turning in reverse AWARNING Avoid turning at sharp angles in reverse as tipover and severe injury may result 78 RIDING Safe Riding Tips Riding On Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel or during cold freezing weather s
42. ations 10 Front Grease Locate grease fitting and Every 3 Drive Axle U Joint AWD Models 11 Ball Joint x Grease kk 12 FrontA Arm Pivot Grease kk Shaft A 13 Counter SAE Balance 10 30 Housing 400 14 Upper steering Post Grease Bushing a 96 grease with grease gun months or 50 hours Locate fitting on back side of struts and grease with grease months or gun Locate fitting on pivot shaft Every 3 and grease with grease gun months or 50 hours Check level on dipstick and Check add oil as necessary monthly Change annually To change and oil see page 125 change annually Locate fitting on steering post Every 3 and grease with grease gun months or 50 hours MAINTENANCE AND LUBRICATION Lubrication Recommendations 13 Counterbalance Dipstick 10 Axle Cardan Front Drive AWD Models 14 Steering Post Bushing oS 9 4 O clock 12 Front A Arm RON position Pivot Shaft A 11 Ball Joint 97 MAINTENANCE AND LUBRICATION Lubrication Recommendations 15 Rear Axle Locate fittings and grease Every 3 Bearing Grease months or ae 50 hours 16 Swing x Locate fittings on swing arm Monthly or Arm Grease and grease with grease gun at 20 Bushings ite hours 17 Upper Locate fittings and grease Semi Control Arms Grease annually kk A 18 Lower Locate fittings and grease Semi Control Arms Grease annually EN 19 Rear Locate fitting an
43. ator to shift position as needed during operation It is not for carrying passengers AWARNING Indicates a potential hazard that could result in serious injury or death 23 SAFETY Operator Safety 24 4 WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces including sidewalks paths parking lots and driveways WHAT CAN HAPPEN The ATV tires are designed for off road use Paved surfaces may seriously affect handling and control of the ATV and may cause the vehicle to go out of control HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement whenever possible If you must ride on a paved surface go slowly and do not make sudden turns or stops SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Operating this ATV on public streets roads or highways WHAT CAN HAPPEN You can collide with another vehicle HOW TO AVOID THE HAZARD Never operate this ATV on any public street road or highway even a dirt or gravel one In many states it is illegal to operate ATVs on public streets roads and highways 25 SAFETY Operator Safety 26 4 WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet eye protection and protective clothing WHAT CAN HAPPEN Operating without an approved helmet increases your chances of a severe head injury or death in the event of an accident Operating without eye protection can result in an accident and i
44. ays check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill 33 SAFETY Operator Safety 34 4 WARNING POTENTIAL HAZARD Going down a hill improperly WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in the Owner s Manual See page 82 NOTE A special technique is required when braking as you go downhill Always check the terrain carefully before you start down any hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side Go straight down the hill where possible SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner s Manual on level ground See page 83 Be very careful when turning on any hill Avoid crossing the sid
45. be clean and free of burrs nicks or scratches 14 Reinstall drain plug 15 Remove dipstick and add the amount of oil indicated in your Owner s Manual Supplement Reinstall dipstick NOTE If sump is not drained add about 1 3 4 quarts initially 16 Place gear selector in neutral and set parking brake 17 Start engine and let it idle for one to two minutes Stop engine and inspect for leaks Dipstick 18 Re check oil level on the dipstick and add oil Filter as necessary to bring the level to the upper mark on the dipstick 19 Dispose of used filter and oil properly 110 MAINTENANCE AND LUBRICATION Lubrication Oil Filter and Change Magnum 325 2x4 Magnum 325 4x4 Trail Boss Oil and Filter Change 1 2 11 Place vehicle on a level surface Crankcase Drain Run engine two to three minutes until warm Stop engine Clean area around drain plug Place a drain pan beneath engine crankcase and remove drain plug CAUTION Oil may be hot Do not allow hot oil to come into contact with skin as serious burns may result Allow oil to drain completely Replace sealing washer on drain plug NOTE The sealing surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches Reinstall drain plug and torque to 14 ft lbs 19 Nm Place shop towels beneath oil filter Using an oil filter wrench turn filter counterclockwise to remove Using a clean dry cloth clean filter seali
46. behind you When it is safe to proceed go slowly SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires on this ATV or operation of this ATV with improper or uneven tire pressure may cause loss of control and increases the risk of an accident HOW TO AVOID THE HAZARD Always use the size and type tires specified in the Owner s Manual Supplement for this vehicle Always maintain proper tire pressure as described in the Owner s Manual Supplement 4 WARNING POTENTIAL HAZARD Operating this ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories All parts and accessories added to this vehicle should be genuine Polaris Industries Inc or equivalent components designed for use on this ATV and should be installed and used according to instructions If you have questions consult an authorized Polaris ATV dealer 39 SAFETY Operator Safety 40 4 WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident HOW TO AVOID THE
47. ch as large rocks or fallen trees Always follow proper procedures when operating over ob stacles as described in this manual Always be careful of skidding or sliding On slippery surfaces such as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control Avoid operating the ATV through deep or fast flowing water If you cannot avoid water which exceeds the recommended maxi mum depth pg 84 go slowly balance your weight carefully avoiding sudden movements maintain a slow and steady forward motion do not make sudden turns or stops and do not make sud den throttle changes Wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them lightly several times to let friction dry out the pads SAFETY Key Safety Issues e Always be sure there are no obstacles or people behind you when you operate in reverse When it is safe to proceed in reverse go slowly Avoid turning at sharp angles in reverse e Always use the size and type tires specified in this manual Always maintain proper tire pressure as described in this manual e Never modify an ATV through improper installation or use of ac cessories e Never exceed the stated load capacity for an ATV Cargo should be properly distributed and securely attached Reduce speed and fol low instructions in this manual for carrying cargo or pulling a trail er Allow greater distance for braking e A
48. cle handling which could cause an accident resulting in serious injury or death Follow the safeguards listed below to prevent this type of situation Important Safeguards Maintain proper tire pressure according to charts below Improper tire inflation may affect ATV maneuverability Do not use improper tires The use of non standard size or type tires may affect ATV handling Make certain the wheel are installed properly If wheels are improperly installed it could affect vehicle handling and tire wear Wheel Removal Procedure 1 Stop the engine place the transmission in gear and lock the parking brake 2 Loosen the wheel nuts slightly 3 Elevate the side of the vehicle by placing a suitable stand under the footrest frame 4 Remove the wheel nuts and remove the wheel 139 MAINTENANCE AND LUBRICATION Adjustments Wheel Installation 1 With the transmission in gear and the parking brake locked place the wheel in the correct position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation 2 Attach the wheel nuts and finger tighten them 3 Lower the vehicle to the ground 4 Securely tighten the wheel nuts according to the chart found on page 140 The following items should be checked occasionally for tightness or if they have been loosened for maintenance service Wheel Nut Torque Specifications Front 3 8 20 Ft Lbs
49. d cause loss of traction or vehicle control which could result in an accident including an overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain Always be especially cautious on these kinds of terrain 31 SAFETY Operator Safety 32 4 WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN ATV could go out of control causing a collision or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the Owner s Manual See page 78 Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speed 4 WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level surfaces or small hills HOW TO AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting large hills Never operate ATV on hills steeper than 25 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the Owner s Manual See pages 80 through 83 Alw
50. d grease Semi Wheel Hub Grease annually Bearing Carri A er 20 Rear Anti Locate fitting and grease Semi Roll Bar Grease annually More often under severe use such as wet or dusty conditions Polaris Premium all Season Grease or grease conforming to NLGI No 2 such as Conoco Superlube M or Mobilegrease Special Grease every 500 miles or before long periods of storage or after pressure washing or after submerging in water Always use Polaris Premium U Joint Lube for maximum service of these driveline components PN 2871515 3 0z PN 2871551 14 oz A When suspension action becomes stiff or after washing NOTE Hours are based on 10 mph average 98 MAINTENANCE AND LUBRICATION Lubrication Recommendations 15 Rear Axle Bearing INDEPENDENT REAR SUSPENSION 18 Lower Control 17 Upper Control Arm Ly Fe 18 Lower Control J gt Arm ie Anti 19 Rear Wheel Hub Bearing f Carrier 99 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance work Maintenance Servicing Servicing Interval Date Dealer Performed or Person Ee a Cem 100 MAINTENANCE AND LUBRICATION Engine Cooling System Coolant Level The recovery bottle 1 located on the left side of the machine must be maintained between the minimum and maximum levels indicated on the recovery bottle The engine coolant level is controlled o
51. ded to this ATV have been approved by Polaris Familiarize yourself with their function and affect on the ATV 11 SAFETY Safety Decals and Locations NOTE Warning decals have been placed on the vehicle for your protection Read and follow the instructions on each decal carefully In the event any decal becomes illegible or comes off contact your Polaris dealer for a replacement Any safety decal needing replacement will be provided by Polaris at no charge The part number is printed on the decal 12 SAFETY Safety Decals and Locations 4 WARNING Improper ATV use can result in SEVERE INJURY or DEATH DOS ALWAYS USE NEVER USE NEVERCARRY NEVER USE AN APPROVED ONPUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate e without proper training or instruction e at speeds too fast for your skills or the conditions e 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 e use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns e avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS IF OWNER S MANUAL IS MISSING CONTACT YOUR POLARIS DEALER FOR A REPLACEMENT 1997 2000 7079083 13 SAFETY Safety Decals and Locations 14
52. duced or used without the written permission of Polaris Industries Inc Illustrations included in this manual are general representations of parts having a similar function Your model may differ AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE An ATV handles differently from other vehicles including motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers such as turning and driving on hills or over obstacles if you fail to take proper precautions SAFETY Key Safety Issues SERIOUS INJURY OR DEATH can result if you do not follow these instructions Read this manual and all labels carefully and follow the operating procedures described Never operate an ATV without proper instruction Take a training course Beginners should receive training from a certified instruc tor Contact an authorized Polaris ATV dealer or call Polaris at 1 800 342 3764 to find out about the training courses nearest you Never allow anyone under 16 years of age to operate this ATV Never permit a guest to operate this ATV unless the guest has read this manual and all product labels and has completed a certified training course Always avoid operating an ATV on any paved surfaces including sidewalks driveways parking lots and streets Never operate an ATV on any public street road or highway even a dirt or gravel one Never operate an ATV without wearing an approved helmet that fits properly You should also w
53. dure is only required if the cooling system has been drained for maintenance and or repair However if the recovery bottle Lirwutl has run dry the level in the radiator should be inspected and coolant added if necessary To access the radiator pressure cap Gen III A To access the pressure cap clean the area around the oil cap and remove the oil cap 2 cycle models Remove front cover by placing your fingers under the front of the cover and pulling upward Reinstall oil cap Gen IV B Using the tool provided remove the four screws securing front rack 2 Remove front cover 3 by placing your fingers under the front of the cover and pulling upward 102 MAINTENANCE AND LUBRICATION Engine Cooling System NOTE Use of a non standard pressure cap will not allow the recovery system to function properly If the cap should need replacement contact your dealer for the correct replacement part To insure that the coolant maintains its ability to protect the engine it is recommended that the system be completely drained every two years and a fresh mixture of antifreeze and water be added Polaris recommends the use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water NOTE Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water NOTE Always follow the manufacture
54. e The fluid should be kept between the maximum and minimum marks 48 CONTROLS AND FEATURES Controls Engine Fuel and Oil System Fuel System The fuel tank filler cap 1 is located directly behind the handlebar Refer to your owner s Manual Supplement for tank capacity Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane The fuel valve is located on the left side of the front fender and has three positions OFF For vehicle storage and whenever transporting RES ON For normal operation RES For reserve supply in the event of main supply exhaustion NOTE There is about a 7 OFF to 10 mile 11 2 to 16 km range on reserve gas Always refill the gas tank as soon as possible after having used the reserve supply Always return valve to on position after refueling machine Engine Fuel Safety Fuel Filter The Polaris ATV is equipped with an in line fuel filter ON This filter should be replaced by your dealer after every 100 hours of operation or annually Do not attempt to clean the fuel filter 49 CONTROLS AND FEATURES Controls Engine Fuel and Oil System AWARNING 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 whe
55. e go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control 41 SAFETY Operator Safety 42 4 WARNING After a rollover or an accident have a qualified service dealer check the complete machine including but not limited to brakes throttle and steering for possible damage 4 WARNING Safe operation of this rider active vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturns and loss of control which could result in severe injury or death 4 WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death Always remove the ignition key when the vehicle is not in use CAUTION Keep combustible materials away from exhaust system Fire may result AWARNING Indicates a potential hazard that could result in serious injury or death CONTROLS AND FEATURES Controls Engine Electrical Switches AWARNING Activating the override button while throttle is open can cause loss of control resulting in severe injury or death 1 Override Switch Reverse Speed Limiter This vehicle is equipped with a reverse Gee RUN GEE speed limiter system To obtain additional power while backing up depress the ae override button NOTE The override 3 switch also allows activation of Demand 4 Drive All Wheel Drive in revers
56. e if Demand 4 Drive switch is on 2 Main Switch To start the engine slide the stop switch to the center run position and turn the main key switch clockwise past the on position Release the key when the engine starts AWARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death Always remove the ignition key when the vehicle is not in use 3 Engine Stop Switch The engine will not start or run when the switch is in its off position Its purpose is to provide the operator with a quick means of engine shutdown in case of stuck throttle or other emergency NOTE Both the main switch and the emergency engine stop switch shut off all electrical power to the entire vehicle including lights To stop the engine slide the stop switch right or left to the off position 43 CONTROLS AND FEATURES Controls Engine Throttle and Choke AWARNING Do not start or operate an ATV with sticking or improperly operating throttle controls A stuck or improperly operating throttle could cause an accident resulting in severe injury or death Always contact your dealer for service repairs whenever throttle problems arise Failure to check or maintain proper operation of the throttle system can result in the throttle lever sticking during riding and cause an accident Always check the lever for free movement and return before starting
57. e wear Auxiliary Brake Systems Your ATV s auxiliary brake system is intended to be used as a backup for the main brake system Should the main system fail the rear brake can be activated by depressing the foot pedal on the inside of the right floorboard All Polaris ATVs have hydraulic brake systems The hydraulic auxiliary brake system will not require adjustment NOTE Since this is a rear brake only it will not be as effective as the all wheel system 135 MAINTENANCE AND LUBRICATION Adjustments Ca rburetor Engine Idle RPM Adjustment 2 Cycle Engines If the engine idle speed is not satisfactory and all other conditions are favorable the carburetor can be adjusted as follows Warm up the engine by running the vehicle approximately five minutes Place the transmission in gear with the parking brake applied Adjust the carburetor idle screw in or out until the desired idle RPM is reached Turning the screw in Air Screw clockwise will raise RPM Turning the screw out counterclockwise will lower RPM The following variations to air screw adjustment for 2 Cycle engines should be noted 136 For improving cold weather start and reducing audible detonation noise the air screw can be closed from 1 2 to 1 turn by turning the screw clockwise During hot weather and or high altitude operation the air screw can be adjusted for smooth operation by approximately 2 turns counter clockwise MAINTENANCE AN
58. e following checks are recommended to keep the brake system in good operating condition How often they need checking depends upon the type of driving that has been done e Keep fluid level in the master cylinder reservoirs as described on page 46 Normal functioning of the diaphragm is to extend into the reservoir as fluid level drops If the fluid level is low and the diaphragm is not extended a leak is indicated and the diaphragm should be replaced Always fill the reservoir as indicated whenev er the cover is loosened or removed to insure proper diaphragm operation Use Polaris DOT 3 brake fluid e Check brake system for fluid leaks e Check brake for excessive travel or spongy feel e Check friction pads for wear damage and looseness e Check security and surface condition of the disc e Pads should be changed when friction material is worn to 3 64 1 cm A or about the thickness of a dime 134 MAINTENANCE AND LUBRICATION Adjustments Rear and Auxiliary Brake Rear Brake The rear brake is a hydraulic disc type brake which is activated by the same lever which activates the front brake system The rear brake system is self adjusting and requires no maintenance other than periodic checks of the pads for wear e Pads should be changed when the friction material is worn to 3 64 1 cm which is about the thickness of a dime e Inspect the brake disc spline and pad wear surface for excessiv
59. e intervals are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use such as operation in wet or dusty areas should be inspected and serviced more frequently If you are not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Inspect clean lubricate adjust or replace parts as necessary NOTE Inspection may reveal the need for replacement parts Always use genuine Polaris parts available from your Polaris dealer Service and adjustments are critical If you are not familiar with safe service and adjustment procedures have a qualified dealer perform these operations 4 CAUTION Due to the nature of the adjustments marked with a ll on the following chart it is recommended that service be performed by an authorized Polaris dealer More often under severe use such as dirty or wet conditions to purge water or dirt contamination from grease fittings and other critical components Emission Control System Service California 4 Cycle NOTE Some 4 Cycle models may have an additional California only emissions warranty Please refer to your owner s manual supplement to determine if this applies to your vehicle 88 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Item Hours or When Remarks Miles lie Brake System Pre ride inspection item ma Auxiliary Brake Pre ride inspection
60. e of a steep hill if possible When crossing the side of a hill Always follow proper procedures as described in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV 35 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Stalling rolling backwards or improperly dismounting while climbing a hill WHAT CAN HAPPEN Could result in ATV overturning HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill If you lose all forward speed Keep weight uphill Apply the brakes Lock parking brake after you are stopped If you begin rolling backwards Keep weight uphill never apply engine power Never apply the rear brake while rolling backwards Apply the single lever brake gradually When fully stopped apply rear brake as well and then lock parking brake Dismount on uphill side or to either side if pointed straight uphill Turn the ATV around and remount following the procedure described in the Owner s Manual See page 83 ES 36 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or a collision Could cause the ATV to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Use extreme caution when riding over large obstacles such as large rocks or fallen trees If you cannot avo
61. e of unauthorized lubricants chemicals or fuels that are not compatible with the ATV The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law 174 WARRANTY ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service you must take it to a Polaris dealer authorized to repair Polaris ATVs When requesting warranty service you must pr
62. e replace if necessary pre ride inspection item Choke Enricher 50 hrs 6 Inspect adjust lubricate Cable months replace if necessary Coolant strength 100 hrs 6 Inspect strength seasonal pressure test system months ly pressure test system annually Front hubs fluid 50 hrs Check monthly check AWD Padi Shift linkage 50 hrs Inspect adjust ating Drive belt 50 hrs 6 Inspect replace if neces months sary Steering 50 hrs 6 Inspect daily lubricate months Front Suspension 50 hrs 6 Inspect lubricate tighten months fasteners Rear Suspension 50 hrs 6 Inspect tighten fasteners months Drive Chain s 50 hrs 6 Inspect daily adjust and months _ lubricate if needed Spark Plug 100 hrs 12 Inspect replace if neces months sary Rear Axle 50 hrs 6 Inspect bearings Lube months 91 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule 4 CAUTION Due to the nature of the adjustments marked with a ll on the following chart it is recommended that service be performed by an authorized Polaris dealer gt More often under severe use such as dirty or wet conditions to purge water or dirt contamination from grease fittings and other critical components Emission Control System Service California 4 Cycle NOTE Some 4 Cycle models may have an additional California only emissions warranty Please refer to your owner s manual supplement to determine if this applies to your vehicle Item Hou
63. eak at cranking speeds The decompressor senses when the engine is spinning fast enough to start and restores compression for starting CAUTION Do not extend the starter rope so far that it stops This will cause damage to the recoil assembly Make sure the manual start handle is fully seated on the recoil housing especially when travelling in wet areas If it is not sealed properly water may enter the recoil housing and damage components 1 Be certain your vehicle is on a level surface and the parking brake is set See page 74 2 Take the machine out of gear 3 Grasp the recoil starter tightly and pull slightly until the starter mechanism engages 4 Pull the rope abruptly to start the engine 57 CONTROLS AND FEATURES Features Exclusive AWD System All Wheel Drive Polaris 4 wheel drive ATVs are equipped with a unique Polaris exclusive Demand 4 Drive AWD system which is activated by a switch 1 on the right handlebar When the switch is off the ATV is in 2 wheel drive at all times When the switch is on the ATV is in Demand 4 Drive and the AWD indicator 2 will light When in AWD the front 2 wheels will automatically A engage anytime the rear wheels a7 lose traction When the rear l LFS wheels regain traction the front E T wheels will automatically disengage NOTE The override switch also allows activation of Demand 4 Drive AWD in reverse if Demand 4 Drive switch is
64. ealer to find out about the accessories available for your machine 145 MAINTENANCE AND LUBRICATION Lights Adjustment Replacement Headlight Lamp Replacement AWARNING Keep your headlights and taillights clean Poor lighting while riding can result in an accident causing severe injury or death 4 CAUTION Do not service while headlight is hot Serious burns may result Do not touch a halogen lamp with bare fingers Oil from your skin leaves a residue causing a hot spot which will shorten the life of the lamp Headlight Lamp Replacement Scrambler 1 Remove wire harness connector from the back of headlight 2 Grasp bulb housing turn counterclockwise and remove bulb 3 Install bulb into headlight housing and rotate clockwise firmly NOTE Bulb is to be positioned so the harness installs into the lamp at the bottom 4 Reinstall connector 146 MAINTENANCE AND LUBRICATION Lights Adjustment Replacement High Beam Headlight Adjustment The headlight beam can be adjusted up and down 1 2 3 Place the vehicle on a level surface with the headlight approximately 25 7 6 m from a wall Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height Start the engine and turn the headlight switch to high beam Observe headlight aim The most intense part of the headlight beam should be aimed 2 5 1 cm below the mark placed on the wall in step 2
65. ear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants Never consume alcohol or drugs before or while operating this ATV Never operate at excessive speeds Always travel at a speed which is proper for the terrain visibility and operating conditions and your experience Never attempt wheelies jumps or other stunts Always inspect your ATV each time you use it to make sure it is in safe operating condition Always follow the inspection and main tenance procedures and schedules described in this manual Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation Always go slowly and be extra careful when operating on unfamil iar terrain Always be alert to changing terrain conditions when operating the ATV Never operate on excessively rough slippery or loose terrain Always follow proper procedures for turning as described in this manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speed Always have the ATV checked by an authorized Polaris dealer if it has been involved in an accident SAFETY Key Safety Issues 10 Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills as described in this manual Check the terrain carefully before you start up any hill N
66. eck condition and pressures 2 Fuel and oil tanks fill both tanks to their proper levels 3 All brakes check operation adjustment and fluid level includes auxiliary brake 4 Throttle check for free operation and closing 5 Headlight Taillight Brakelight check operation of all indicator lights and switches 6 Engine stop switch check for proper function 7 Wheels check for tightness of wheel nuts and axle nuts check that axle nuts are secured by cotter pins 8 Drive chain condition and slack refer to drive chain adjustment 9 Air cleaner element check for dirt clean or replace 10 Steering check for free operation noting any unusual looseness in any area 11 Loose parts visually inspect vehicle for any damaged components or loose nuts bolts or fasteners 12 Operators helmet goggles and clothing 13 Engine coolant Liquid Cooled Models Only check for proper level at the recovery bottle 66 OPERATION Break In Period 2 Cycle Engines The break in period for your new Polaris ATV is defined as the time it takes to use the first tank of gasoline No single action on your part is as important as a proper break in period Careful treatment of a new engine will result in more efficient performance and longer life for the engine Perform the following procedures carefully CAUTION Use only Polaris injection oil Never substitute or mix oil brands Serious engine damage and voiding of warranty can result
67. emain alert and be prepared to take emergency action This may include quick dismounting of the ATV Sree eb AWARNING Indicates a potential hazard that could result in serious injury or death 80 RIDING Safe Riding Tips Sidehilling Sidehilling your ATV is one of the most dangerous types of riding and should be avoided if possible In the event you do enter into a situation where sidehilling is necessary always 1 Slow down 2 Lean into the hill transferring your upper body weight toward the hill while keeping your feet on the footrests 3 Steer slightly into the hill to maintain vehicle directions If vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately AWARNING Improperly crossing hills or turning on hills can be dangerous Loss of vehicle control or overturning of the ATV could occur causing severe injury or death 81 RIDING Safe Riding Tips Traveling Downhill Whenever descending a hill always 1 Drive directly downhill 2 Transfer your weight to the rear of the vehicle 3 Slow down 4 Apply the brakes slightly to aid in slowing Familiarize yourself with the auxiliary rear brake pedal and its use in the event loss of normal service brakes occurs AWARNING Do not travel at excessive speeds It is dangerous and can cause loss of vehicle control and tipping resulting in severe injury or death 82 RIDING
68. engine two to three minutes until warm Stop engine Clean area around drain plug Place a drain pan beneath engine crankcase and remove drain plug CAUTION Oil may be hot Do not allow hot oil to come into contact with skin as serious burns may result Allow oil to drain completely Replace sealing washer on drain plug NOTE The sealing surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches Reinstall drain plug and torque to 14 ft Ibs 1 9 kgm Place shop towels beneath oil filter Using an oil filter wrench turn filter counterclockwise to remove Using a clean dry cloth clean filter sealing surface on crankcase Lubricate O ring on new filter with a film of engine oil Check to make sure the O ring is in good condition Install new filter and turn by hand until filter gasket contacts the sealing surface then turn an additional 1 2 turn 115 MAINTENANCE AND LUBRICATION Lubrication Oil Filter and Change Cont Xpedition 425 12 Remove dipstick and fill sump with 5 5 quarts 5 2 1 of Polaris Premium 4 synthetic oil 13 Shift machine into neutral and set parking brake 14 Start the engine and let it idle for one to two minutes Stop the engine and inspect for leaks 15 Re check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick 16 Dispose of used filter and oil properly NOTE D
69. equency 1 Engine Oil 2 Cycle Polaris Injection Oil 2 Engine Oll 4 Cycle Polaris Premium Synthetic gear case lube 4 Transmis sion Oil 5 Front Gearcase Oil 6 Front Prop Grease Shaft U joints 7 Front Grease Propshaft Yoke O Ring chain lube 9 Demand 4 Hubs All Wheel Drive ATVs 94 Fill oil tank See page 49 Add to proper level on dip stick See page 105 Maintain level between fill lines See page 46 See Page 117 See Page 122 Models with Visco drive require special lubricant See your owner s manual sup plement for requirement Locate Fittings and Grease Locate fittings and grease 3 pumps maximum Lubricate as often as re quired Before each ride in wet conditions Remove set screw in hubs Rotate wheels to 4 O clock position If lubri cant is not visible add more Reinstall set screw As needed when refuel ing Check level daily As required change every two years or 200 hours Change annually or at 100 hours Change annually or at 100 hours Every 3 months or 50 hours Every 3 months or 50 hours As required Annually or at 100 hrs MAINTENANCE AND LUBRICATION Lubrication Recommendations O 4 Transmission T A dipstick Operating Range 4 Transmission plug Fill plug 6 Front Prop Shaft U Joint 7 Propshaft Yoke 95 MAINTENANCE AND LUBRICATION Lubrication Recommend
70. esent your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Engine Oil 1 Always use Polaris engine oil 2 Never substitute or mix oil brands as serious engine damage and voiding of warranty can result 175 INDEX Adjustments 4 133 148 Air Cleaner 004 127 128 Air Filter Air Box 128 169 All Wheel Drive 58 59 Automatic Transmission 52 Auxiliary Power Outlet 68 Backing Upei resone tree cous esate ss oe 86 Battery Installation 162 Battery Maintenance 161 163 170 Battery Removal 4 162 Brake Fluid 00 48 Brake St tte ee Soe aasre Saye 53 Brake Auxiliary Mechanical 48 135 Brake Front 0 00000 134 Brake Parking 0 47 Brake Rear
71. ever climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes Never go over the top of any hill at high speed Always follow proper procedures for going down hills and for brak ing on hills as described in this manual Check the terrain careful ly before you start down any hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side Go straight down the hill where possible Always follow proper procedures for crossing the side of a hill as described in this manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV Never attempt to turn the ATV around on any hill until you have mastered the turning technique described in this manual on level ground Avoid crossing the side of a steep hill if possible Always use proper procedures if you stall or roll backwards when climbing a hill To avoid stalling maintain a steady speed when climbing a hill If you stall or roll backwards follow the special procedure for braking described in this manual Dismount on the uphill side or to either side if pointed straight uphill Turn the ATV around and remount following the procedure described in this manual Always check for obstacles before operating in a new area Never attempt to operate over large obstacles su
72. f an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the Owner s Manual 4 WARNING POTENTIAL HAZARD Removing hands from handlebars or feet from footrests during operation WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off the ATV If you remove a foot from the footrest your foot or leg may come into contact with the rear wheels which could injure you or cause an accident HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of your ATV during operation 29 SAFETY Operator Safety 30 4 WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough slippery or loose terrain WHAT CAN HAPPEN Coul
73. ght pressure to the lever until braking action is normal e Avoid operating the ATV through deep or fast flowing water If you cannot avoid water which exceeds the recommended maxi mum depth go slowly balance your weight carefully avoid sud den movements maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes NOTE After running the vehicle in water it is critical your machine is serviced as outlined in the maintenance chart beginning on page 88 The following areas need special attention engine oil transmission oil front and rear gearcases and all grease fittings If your vehicle becomes immersed and it is impossible to take it to a dealer before starting follow the steps described on page 154 It is still important the vehicle be serviced by your dealer at the first opportunity 84 RIDING Safe Riding Tips Trail Obstacles Keep Alert Look ahead and learn to read the trail as you ride Stay on the right side of the trail if possible and be constantly alert for hazards such as logs rocks and low hanging branches AWARNING Not all obstacles are visible Travel with caution on trails severe injury or death can result if your machine comes in contact with a hidden obstacle 85 RIDING Safe Riding Tips Backing Up Avoid backing up on steep inclines Always back slowly When in reverse apply the brakes lightly for sto
74. hain Slack Adjustment Models with Concentric Drive CAUTION Never adjust or operate the vehicle with the rear drive chain too loose or too tight as severe damage to the transmission and drive components can result Check the amount of chain slack by moving the vehicle slightly forward to gain slack at the top side of the rear chain At this point the chain should have 3 16 3 8 48 cm 95 cm deflection 1 If the chain needs adjustment use the following procedure 3 16 3 8 48 cm 95 cm Deflection 143 MAINTENANCE AND LUBRICATION Adjustments Adjustment Procedure 1 Loosen chain guide 2 Loosen two eccentric locking bolts 2 3 Loosen caliper mounting bracket bolts located under the axle 4 Insert a pin punch through the sprocket hub and into the eccentric housing 5 Roll the ATV forward or Nee as back to adjust chain slack to Proper Splicelink the proper tension Clip Opening E 6 Tighten the eccentric Position locking bolts to 30 ft Ibs 9 kg m for machines without the hitch and 45 ft lbs 13 7 kg m for machines with a hitch 7 Tighten caliper mount bolts 10 12 ft Ibs 1 4 1 7 kg m Remove pin punch 9 Roll ATV foward checking chain tension in several places around the chain NOTE The chain is adjusted correctly when the tightest portion of the chain has approximately 3 8 10mm of deflection 10 Position chain guide to allo
75. he machine with a genuine Polaris ATV cover NOTE Do not use plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation 167 MAINTENANCE AND LUBRICATION Cleaning and Storage If you choose not to use Polaris fogging Oil perform the following procedure 1 Support the front end of the machine so the engine is level or tilted slightly rearward 2 Remove spark plug s Rotate piston to BDC and pour approximately two ounces of Polaris 2 Cycle Injector oil into the cylinder 3 Turn the engine over several times to ensure coverage of piston rings cylinder walls and crankshaft bearings 4 Treat the fuel system with Polaris Carbon Clean 5 If Polaris fuel system additive is not used fuel tank fuel lines and carburetor should be completely drained of gasoline to eliminate any fuel remaining in the carburetor run the engine until it stops Transporting Whenever the ATV is to be transported the following measures should be taken 1 Turn off the engine and remove the key It may be lost if not removed 2 Turn the fuel valve to off 3 Be certain the fuel cap oil cap and seat are installed correctly 4 Always tie the frame of the ATV to the transporting unit securely using suitable straps or rope 5 Always place the transmission in gear and lock the parking brake 168 TROUBLESHOOTING Clutch Drive Belt amp Cover Related Issues Diagnosis Po
76. he owner you have the following responsibilities to make sure this system remains safe e Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur This system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components e Routine maintenance is the responsibility of the owner Al ways follow recommended maintenance procedures See your dealer e This PVT system is intended for use on Polaris products only e The PVT housing must be securely in place during opera tion Failure to comply with this warning can result in severe injury or death Low Range Use May Reduce PVT Operating Temperatures The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements As engine speed increases the force exerted on the movable drive sheave by the flyweights also increases This in turn increases the amount of pinch applied to the drive belt Similarly if the engine speed decreases the amount of centrifugal force decreases reducing the amount of belt pinch 158 MAINTENANCE AND LUBRICATION PVT System On Polaris ATVs the approximate gear ratio difference between high and low range is 1 2 25 This difference in gearing affects the operation of the PVT especially at speeds less than 7 MPH due to the system s dependence on engine speed For ex
77. hetic oil This lubricant has been specially formulated for low smoke low odor and high lubricity We recommend continued use of this oil or Premium 2 cycle oil Premium 2 Cycle Oil Polaris also has a TC W3 premium oil available for use in all of our 2 cycle products We highly recommend its use if premium gold synthetic is not used The only oil recommended for this ATV is Polaris brand oil Polaris Premium 2 cycle oils will readily mix with each other however do not mix Polaris Premium 2 cycle oils with any other oils as they may not be compatible and engine damage may occur 104 MAINTENANCE AND LUBRICATION Lubrication 4 Cycle Premium 4 Synthetic Lubricant CAUTION Use only Polaris Premium 4 All Season synthetic oil PN 2871271 or API certified SH oil Never substitute or mix oil brands Serious engine damage and voiding of warranty can result Polaris Premium 4 All Season Synthetic engine oil has been specially formulated for use in Polaris 4 cycle engines It is a fully synthetic high performance multi viscosity oil designed to provide the ultimate in lubrication performance and protection Premium 4 possesses unsurpassed film strength over the widest possible temperature range It resists viscosity and frictional breakdown in ambient temperatures from 40 F to 120 F Its exceptional frictional properties result in more efficient operation more power output lower fuel consumption and easier starting i
78. his ATV without proper instruction WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Polaris Industries Inc They should then regularly practice the skills learned in the course and the operating techniques described in the Owner s Manual For more information about the training course contact an authorized ATV dealer or call Polaris at 1 800 342 3764 4 WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV WHAT CAN HAPPEN Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child Even though a child may be within the age group for which some ATVs are recommended he or she may not have the skills abilities or judgment needed to operate the ATV safely and may be involved in a serious accident HOW TO AVOID THE HAZARD No one under 16 should operate a Polaris ATV SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Carrying a passenger on this ATV WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passenger HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to allow the oper
79. id obstacles always follow proper procedures as described in the Owner s Manual 4 WARNING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN You may lose control of the ATV You may also regain traction unexpectedly which may cause the ATV to overturn HOW TO AVOID THE HAZARD On slippery surfaces such as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control 37 SAFETY Operator Safety 38 4 WARNING POTENTIAL HAZARD Operating this ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast flowing water you cannot avoid water which exceeds the recommended maximum depth pg 84 go slowly balance your weight carefully avoiding sudden movements maintain a slow and steady forward motion do not make sudden turns or stops and do not make sudden throttle changes Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the pads 4 WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN You could hit an obstacle or person behind you resulting in severe injury HOW TO AVOID THE HAZARD When you select reverse gear make sure there are no obstacles or people
80. is reached first the reminder will turn on in the LCD window 61 CONTROLS AND FEATURES Features Electronic Speedometer When the programmed hours are reached SEr hr will light when the programmed distance is reached SErdIS will light Each time the vehicle is started the reminder will turn on and remain lit until the button is pushed or the speedometer is reprogrammed for the next service interval Accessing Sub menu Features There are two methods for accessing the sub menu 1 Press and hold the button and turn the power on 2 Press and hold the button for 8 seconds Hold the button until the display shows POLArS then release the button The speedometer is now in the sub menu To display each mode press the button once to scroll through the four available functions Each function will be displayed as follows Service Hours SET hr Service Distance SETdIS Miles to Kilometers COnvrT No Menu Changes DOnE Changing Distance Measurement 1 Access the sub menu 2 Select COnvrT and release the button If the last digit in the odometer display is K the current measurement is kilometers if the last digit is M distance is being measured in miles To Set Service Hours 1 Access the sub menu 2 Toggle to SET hr then release the button 3 In3 seconds the LCD will display 5 digits with the left most digit flashing 4 Within 4 seconds press and release the button to change the digit Once the digit is changed once
81. iston rings and ring lands coating the cylinder with a protective film of fresh oil Check and Lubricate Cables Grease Inspect all cables and lubricate with Polaris Cable Lubricant Follow lubrication guidelines in the Maintenance Section of the Service or Owner s Manual to completely grease and lubricate the entire vehicle with Polaris Premium All Season Grease Apply Polaris O ring Chain Lube to the drive chain s Battery Maintenance Remove the battery and add distilled water as required to the proper level Do not use tap water which may contain minerals that reduce battery life Apply Polaris Di Electric Grease to the terminal bolts and terminals Charge the battery at 1 4 amps or less until specific gravity of each cell is 1 265 or greater Store the battery in a cool dry place Charge can be maintained easily by using Polaris Battery Tender charger PN 2871076 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 if the voltage drops below a pre determined point The only thing you need to do is check the fluid level once a month Engine Anti Freeze Test engine coolant strength and change if necessary Coolant should be replaced every 2 years Storage Area Covers Set tire pressure and safely support the ATV with the tires 1 2 off the ground Be sure the storage area is well ventilated Cover t
82. item Tires Pre ride Pre ride Inspect daily pre ride in spection item Frame nuts bolts Pre ride Pre ride Pre ride inspection item fasteners Injector Oil Level Pre ride Pre ride Check when refueling 2 Cycle p gt Air Filter Pre Clean Pre ride Pre ride Inspect Clean fer Coolant Level In Pre ride Pre ride Replace engine coolant spection every two years iz Fuel and oil tanks Fill to proper levels oo Engine Stop Switch Check operation Steering oO Check for free operation jane ___ Box Sediment Pre ride Pre ride Drain deposits whenever Tube visible Headlamp Inspection Pre ride Pre ride Check operation daily ap ply Polaris dielectric grease to connector when replaced Tail lamp inspection Pre ride Pre ride Check operation daily ap ply Polaris dielectric grease to socket when re placed Air Filter Main Ele Weekly Weekly Inspect Replace if neces ment sary 89 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule 4 CAUTION Due to the nature of the adjustments marked with a ll on the following chart it is recommended that service be performed by an authorized Polaris dealer gt More often under severe use such as dirty or wet conditions to purge water or dirt contamination from grease fittings and other critical components Emission Control System Service California 4 Cycle NOTE Some 4 Cycle models may have an additional California only emi
83. l of GL5S 80 90 Weight gear Lube and inspect oil level Oil level should be kept even with the center of the drill point approximately 1 5 8 below the top of the fill hole 4 Reinstall the fill plug Tighten securely 14 ft Ibs 1 93 kgm 5 Check for leaks 1 5 8 123 MAINTENANCE AND LUBRICATION Lubrication Counter Balance Lubrication 400 Engines 1 Counter Balance Drain 2 Crankcase Drain 3 Recoil Drain 4 Starter Pinion Drain The counter balance oil should be checked semi annually and oil should be added or changed as necessary The oil should be changed annually especially before off season storage If the machine is used in wet conditions the oil should be checked more frequently If the oil has a milky appearance it should be changed as soon as possible Failure to properly maintain this important area can result in premature wear or possible failure of the counter balance components Always use SAE 10W30 oil 124 MAINTENANCE AND LUBRICATION Lubrication Procedure for Adding Oil 1 Remove seat and locate dipstick 1 2 Remove dipstick Oil level is shown on dipstick 3 Add SAE 10W30 oil with a transmission fluid funnel until oil is at the proper level on the dipstick If overfilled excess oil will be expelled through the vent hose 4 Reinst
84. le to your dealer for service as soon as possible 159 MAINTENANCE AND LUBRICATION PVT System When To Use Low Range vs High Range The following lists provide a guideline for when to use low range rather than high Low Range e Basic operation at speeds less than 7 MPH e Heavy pulling e Riding through rough terrain swamps mountains etc at low ground speeds High Range e Basic operation at speeds greater than 7 MPH e High ground speeds 160 MAINTENANCE AND LUBRICATION Battery AWARNING Whenever removing the battery disconnect the negative black cable first When reinstalling the battery connect the negative black cable last or an explosive situation could result causing serious injury or death AWARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Replenishing the Battery Fluid A poorly maintained battery will deteriorate rapidly Check the
85. lways remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting FOR MORE INFORMATION ABOUT ATV SAFETY call the Consumer Product Safety Commission at 1 800 638 2772 or Polaris at 1 800 342 3764 Additional Important Information Due to our concern for the safety of our customers and the general public Polaris hereby strongly recommends and requests that consumers not have installed on a Polaris ATV any equipment which is intended to increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes Any modifications to the original equipment of the ATV substantially increase the risk of bodily injury Please be aware that these modifications may create a substantial safety hazard Polaris hereby informs you that the warranty on your ATV is terminated if any such equipment has been added to the ATV or any modifications have been made to the ATV which increase its speed or power We also advise you to strictly follow the recommended maintenance program outlined in this manual This preventive maintenance program is designed to ensure that all critical components on the ATV are thoroughly inspected by your dealer at various mileage intervals NOTE The addition of certain accessories including but not limited to mowers blades tires sprayers or large racks may change the handling characteristics of the ATV Be certain any accessories ad
86. mark on the wall at the same height 3 Start the engine and turn the headlight switch to high beam 4 Observe headlight aim The most intense part of the headlight beam should be aimed 2 5 1 cm below the mark placed on the wall in step 1 NOTE Rider weight must be included on the seat 5 Adjust beam to desired position by turning the adjustment knob 150 MAINTENANCE AND LUBRICATION Lights Adjustment Replacement Headlight Housing Replacement 1 Using a small flat blade screwdriver push in on the lock tab through the two small openings at the front of the headlight pod 2 Lift the pod lightly while depressing the tabs 3 Remove the screw in the back of the headlight pod 4 Remove three Phillips screws O Ring at back of headlight pod 5 Lift pod cover up Disconnect speedometer harnesses from speedometer Unplug indicator light harness and remove pod cover 6 Unplug headlamp from wiring harness 7 Remove O Ring from headlight pivot pins 8 Pull headlight housing up to release from locking tabs 1 8 9 Lift adjusting knob up to Gsm remove from locking tabs Distance from headlamp parting line to end of adjustment knob stop 10 Carefully pull assembly up is 5 1 8 13 cm and out of pod 11 Reverse steps to install new housing and reassemble pod 12 Adjust headlight aim by turning adjusting knob 151 MAINTENANCE AND LUBRICATION Lights Adjustment Replacement
87. n cold temperatures Although Polaris Premium 4 is the only oil recommended for use in this engine use of any API certified SH oil is allowable Oil may need to be changed more frequently if Polaris Premium 4 is not used You will also need to follow the manufacturers recommendations for ambient temperature operation 105 MAINTENANCE AND LUBRICATION Lubrication Oil Pump Adjustment Procedure 400 Engines 1 Before adjusting the oil pump check engine idle RPM and carburetor adjustments which are found in the owner s manual supplement 2 Loosen throttle cable jam nut and turn adjuster in or out until there is 1 16 1 8 16 32 cm of throttle lever travel Oil Pump Adjustment 400 before throttle slide starts to open See Owner s Manual Supplement 3 Place very slight pressure on the throttle lever until all freeplay is removed from throttle cable to the point where the carb slide is just starting to rise 4 Lift boot 1 up off adjuster sleeve 2 Remove the oil pump cover Loosen the cable adjuster locknut Adjust oil pump cable until marks align D when the throttle slide just begins to raise 5 Tighten the locknut 6 Recheck adjustment If correct slide boot all the way down over the upper portion of the bottom nut 3 to ensure good sealing against water entry Reinstall oil pump cover and gasket 106 MAINTENANCE AND LUBRICATION Lubrication Oil Pump Adjustment Procedure
88. n of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your ATV is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage 173 WARRANTY WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any ATV that has been altered structurally modified neglected improperly maintained used for racing or used for purposes other than for which it was manufactured or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the ATV due to fire explosions or any other cause beyond Polaris control This warranty does not cover the us
89. ncreases your chances of a severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved helmet which fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and perception Could result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV 4 WARNING POTENTIAL HAZARD Operating this ATV at excessive speeds WHAT CAN HAPPEN Increases your chances of losing control of the ATV which can result in an accident HOW TO AVOID THE HAZARD Always travel at a speed which is proper for the terrain visibility and operating conditions and your experience 27 SAFETY Operator Safety 28 4 WARNING POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps Don t try to show off SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibility o
90. nd brake lever two or three times and hold it Push the park brake lock 2 into the notches on the master cylinder body Release the brake lever To release the parking brake lock squeeze the brake lever It will return to its released position Important Safeguards The parking brake may relax when left on for a long period of time This could cause an accident Do not leave the vehicle on a hill depending on the parking brake for more than five minutes Always block the downhill side of the wheels if leaving the ATV on a hill or park the ATV in a side hill position 47 CONTROLS AND FEATURES Controls Auxiliary Brake AWARNING Use caution when applying the auxiliary brake Do not aggressively apply the auxiliary brake when going forward or the rear wheels may skid and slide sideways causing loss of control Your Polaris ATV has an auxiliary brake 1 provided as a safety feature It is located on the inside of the right floor board and is operated by the right foot It is intended as a backup to the main brake system especially if the main system becomes inoperative If the rear wheels slide reduce brake pedal pressure to brake the rear wheels without skidding Aggressively applying the rear brake when backing down a hill may cause rear tip over Brake Fluid Level It will be necessary to check the brake fluid level for the auxiliary brake system The reservoir is located under the seat or near the foot brak
91. ng follow the steps outlined below e Move the ATV to dry land or at the very least to water below the foot rests e Turn the fuel valve to OFF e Remove the spark plug e Loosen the carburetor drain screw 1 or remove bowl drain 2 e For two stroke engines remove crank case drain screw as on page 124 e Turn the engine over several times with electric start e Dry the spark plug and reinstall or re place with a new plug e Tighten the carburetor drain screw 1 or reinstall carburetor drain 2 e Reinstall crankcase drain e Turn the fuel valve to ON e Attempt to start the engine If neces sary repeat the drying procedure e Take the machine to your dealer for service as soon as possible whether you succeed in starting it or not If water has been ingested into the PVT follow the procedure on page 159 to dry out the PVT 154 MAINTENANCE AND LUBRICATION Spark Arrestor AWARNING When cleaning the spark arrestor you must follow the safeguards listed below to avoid serious injury or death e Do not perform this operation immediately after the engine has been run because the exhaust system becomes very hot Because of the increased fire hazard make sure that there are no combustible materials in the area when purging the spark arrestor Wear eye protection Do not stand behind or in front of the vehicle while purging the carbon from the spark arrestor Never run the engine in
92. ng surface on crankcase Lubricate O ring on new filter with a film of engine oil Check to make sure the O ring is in good condition Install new filter and turn by hand until filter gasket contacts the sealing surface then turn and additional 1 2 turn 111 MAINTENANCE AND LUBRICATION Lubrication Oil Filter and Change Cont Magnum 325 2x4 Magnum 325 4x4 Trail Boss 12 Remove dipstick and fill sump with 2 quarts 1 9 1 of Polaris Premium 4 synthetic oil 13 Place gear selector in neutral and set parking brake 14 Start the engine and let it idle for one to two minutes Stop the engine and inspect for leaks 15 Re check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick 16 Dispose of used filter and oil properly NOTE Drain Plug Torque 14 ft Ibs 19 Nm Oil Filter Torque Turn by hand until filter gasket contacts the sealing surface then turn an additional 1 2 turn 112 MAINTENANCE AND LUBRICATION Lubrication Oil Filter and Change Xpedition 325 1 2 11 12 Place vehicle on a level surface Oil Drain Run engine two to three minutes until warm Stop engine Clean area around drain plug Place a drain pan beneath engine crankcase and remove drain plug CAUTION Oil may be hot Do not allow hot oil to come into contact with skin as serious burns may result Allow oil to drain completely
93. of your ATV Dealer Imprint SAFETY Understanding Warnings The following two pages identify signal words and symbols that appear in this manual Your safety is involved when these words and symbols are used Become familiar with their meanings before reading the manual The safety alert symbol on your vehicle or in this manual alerts you to the potential for personal injury AWARNING Indicates a potential hazard that could result in serious injury or death 4 CAUTION Indicates a potential hazard that may result in minor personal injury or damage to the machine CAUTION Indicates a situation that may result in damage to the machine NOTE NOTE will alert you to important information or instructions SAFETY Key Safety Issues Protect Your Sport Know all local state province riding laws Respect your vehicle Respect the environment and You will gain the respect of others We also advise you to strictly follow the recommended maintenance program as outlined This preventive maintenance program is designed to ensure that all critical components on this ATV are thoroughly inspected at various intervals All information in this manual is based upon the latest product data and specifications available at the time of printing Polaris Industries Inc reserves the right to make product changes and improvements which may affect illustrations or explanations No part of this manual shall be repro
94. offers the following kits for cold weather operation Oil Tank Cover Engine Heater and Oil Tank Heater These kits reduce moisture accumulation in the oil tank when the ATV is operated in freezing temperatures If you use your ATV all year round it is important to check your oil level frequently A rising oil level could indicate the accumulation of water in the bottom of the oil tank Water in the bottom of the tank can lead to engine damage and must be drained Water accumulation increases as outside temperature decreases The cold weather kits not only reduce moisture accumulation but the heaters provide quicker warm ups and easier starting See your dealer for more information on cold weather operation and what kit will work best for your driving habits 71 OPERATION Carrying Loads Your ATV has been designed to carry a certain amount of load CARGO WEIGHT should be evenly distributed 1 3 on the front and 2 3 on the rear and mounted as low as possible When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions Never exceed the weights specified in your Owner s Manual Supplement Maximum trailer weight 850 lbs 386 kg maximum vertical hitch weight 30 lbs 14 kg Select models may tow up to 1225 556 kg on level ground only with a maximum vertical hitch weight of 35 Ibs 16 kg Refer to your Owner s Manual Supplement to determine your machine s capabilities Know you
95. oggle to SET dIS To Check When Service Is Due By Distance Same as setting Service Hours but toggle to SET dIS To Clear The Service Reminder From The Display The reminder will remain in the LCD window until the button is pushed or it is reprogrammed for the next service interval When this is done the display will return to the normal menu showing odometer trip meter and hour meter If the service interval isn t reprogrammed the reminder will be displayed each time the speedometer is powered up again pushing the button can clear the display AWARNING Indicates a potential hazard that could result in serious injury or death 64 CONTROLS AND FEATURES Features Auxiliary Power Outlet Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights On select models an outlet is located on the front headlight pod To determine if your vehicle is equipped with auxiliary power outlet please check your Owner s Manual Supplement Accessory outlets are available for all models Contact your Polaris dealer for more information 65 OPERATION Pre Ride Inspection AWARNING You must inspect your ATV each time before riding to ensure it is in proper working order If proper inspection is not done severe injury or death could result Use the following checklist to verify your machine is in proper working order each time you ride Item Inspection Procedure 1 Tires ch
96. on There is no limit to the length of time the vehicle may remain in Demand 4 Drive The Demand 4 Drive switch may be turned on or off while the vehicle is moving If the switch is turned off when the front hubs are driving they will not release until the rear wheels regain traction NOTE Select AWD models do not have an AWD switch These models are continuously in All Wheel Drive CAUTION Do not switch on Demand 4 Drive if the rear wheels are spinning This may cause severe drive shaft and hub damage 58 CONTROLS AND FEATURES Features Exclusive AWD System All Wheel Drive Engage the Demand 4 Drive switch before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before turning the Demand 4 Drive switch on Disengaging Wheel Hubs When backing up while in Demand 4 Drive and then going forward one or both hubs may remain engaged If one or both hubs remain engaged they can be disengaged by stopping shifting to and moving in reverse Then proceed in forward again You can tell if only one front hub is engaged if the handlebars pull to one side If both front wheel hubs are engaged steering effort increases but remains balanced from left to right and vehicle speed is somewhat restricted AWARNING If both hubs were engaged and only one released during operation loss of control could result If you experience hub engaging symptoms use the above
97. on carefully use fast brief aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle over turn Belt slippage from water Shift the transmission to neutral or snow ingestion into Using the throttle vary the engine the PVT system rpm from idle to full throttle Re peat several times as required During this procedure the throttle should not be held at the full posi tion for more than 10 seconds Clutch seals should be inspected for damage if repeated leaking oc curs Clutch malfunction For inspection of clutch compo nents please contact your Polaris dealer Poor engine perfor Fouled plugs foreign material in mance gas tank fuel lines or carburetor Contact you dealer for further ser vice information GENERAL RANGE OPERATION GUIDELINES Low Range Heavy pulling basic operational speeds less than 7 MPH riding through rough terrain swamps mountains etc low ground speeds High Range High ground speeds speeds above 7 MPH 170 TROUBLESHOOTING Procedures The following information is provided to help you identify probable causes for questions you may have about the operation of your ATV See your Polaris dealer with any additional questions you may have ENGINE TURNS OVER BUT FAILS TO START Fuel Valve Off No Spark to Spark Plug Clogged Fuel Contact Your Dealer Valve or filter 171 TROUBLESHOOTING
98. ontrols AWARNING The Electronic Throttle Control ETC stops the engine in the event of a throttle system malfunction and is provided for your safety Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms Front and Rear Brakes The brake fluid in the master cylinder which is located on the left handlebar should be checked before each ride The fluid level can be seen through an indicator window 1 on the top of the master cylinder This eye will appear dark when the fluid level is full When fluid needs to be added the eye will be clear NOTE When checking the fluid level the ATV must be on level ground the the handlebars straight If the fluid level is low add DOT 3 PN 2870990 only AWARNING Once a bottle of brake fluid is opened use what is necessary and discard the rest Do not store or use a partial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air This causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of severe injury 46 CONTROLS AND FEATURES Controls Parking Brake AWARNING Always check to be sure that the parking brake has been disengaged before operating the ATV An accident could result causing severe injury if the parking brake is left on while the ATV is operated Setting the Parking Brake 1 Squeeze the left ha
99. or tap water into the battery 162 MAINTENANCE AND LUBRICATION Battery 1 2 3 4 gt 6 NOTE Set the battery in its holder Install the battery vent tube It must be free from obstructions and securely installed Ifnot battery gases could accumulate and cause an explosion The tube should be routed away from the frame and body to prevent corrosion Avoid skin contact with electrolyte severe burns could result First connect and tighten the red positive cable Second connect and tighten the black negative cable Reinstall battery cover and attach the hold down strap Verify that cables are properly routed When your ATV is placed in storage for three months or more the battery should be removed charged to proper level and stored in a cool dry place Before reusing take the battery to your dealer for testing and re charging Power plug leads may need to be bent down so that the battery cov er may be installed When installing a new battery make certain it is fully charged prior to it s initial use Using a new battery that has not been fully charged can damage the battery resulting in a shorter life of the battery It can also hinder vehicle performance AWARNING Indicates a potential hazard that could result in serious injury or death 163 MAINTENANCE AND LUBRICATION Side Panel Removal Gen IV Models Side panel removal may be difficult until the locking tabs and receivers have been
100. ould review this information on a regular basis In the event you purchased a used Polaris ATV from a party other than a Polaris dealer you can obtain this safety training at no charge from any authorized Polaris dealer Failure to follow the warnings contained in this manual can result in SEVERE INJURY OR DEATH NOTE Illustrations used in this manual are for general representation only Your model may differ TABLE OF CONTENTS Vehicle Identification Numbers 6 Safety corer o eae tet s 7 42 Understanding Warnings 0e eee eee 7 Key Safety Issues 2 ex sesacive weed Per te teke es 8 Decals and Locations 2 0 cece eee ee eee nen 12 Operator Saletyo ccee caspian se Pareirs yagi 22 Features and Controls 43 65 COMMOIS r SE E E eae etaubaminmedenne 43 Features a nean Si tear E E Sarees T E 58 Operation i apoia a a a i 66 70 Pre Ride Inspection evcieveedeciwe ek eciaes ees 66 Vehicle Break In Period 060 cee eee ees 67 Starting the Engine 0 2 cece eee 70 Carrying LoadS ifo scone ae cee ae wwe tabi ee es 72 Noise Emission Control System 75 RIGING icewiweccccabemrewseendac da ans 76 87 Pre Ride Inspection 02 c eee cece eee 76 Safe Riding Tips lt 3 sc ns wed naaa naana 77 TABLE OF CONTENTS Maintenance and Lubrication 88 168 Periodic Maintenance Schedule 88 Lubrication Recommendations
101. pecial atten tion must be paid to prevent vehicle turnover Always 1 PA 3 Slow down when entering slippery areas Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward Driving with Demand 4 Drive All Wheel Drive engaged can assist in controlling the vehicle in slippery areas Never apply brakes during a skid Complete loss of ATV control can result Do not operate on excessively slippery surfaces if possible to avoid Always reduce speed and use additional caution CAUTION Severe damage to drive train may occur if the Demand Drive is engaged while the wheels are spinning AWARNING Failure to exercise care when operating the ATV on slippery surfaces can be dangerous Loss of tire traction and vehicle control can result in an accident including an overturn 79 RIDING Safe Riding Tips Traveling Uphill 25 Maximum AWARNING Exercise extreme caution when traveling in hilly terrain Braking and handling are greatly affected Loss of vehicle control or overturning of the ATV could occur causing severe injury or death Whenever traveling uphill always travel straight uphill and Avoid steep hills 25 maximum Keep both feet on the footrests Transfer your weight forward Proceed at a steady rate of speed and throttle opening R
102. position Turn the key off to prevent battery drain 60 CONTROLS AND FEATURES Features Electronic Speedometer CAUTION Do not wash the electronic speedometer with a high pressure washer Wash the unit by hand or with a garden hose High water pressure may allow water to enter the speedometer and cause damage to the electronic components Some Polaris ATVs are equipped with an electronic speedometer which senses vehicle speed from the right hand front wheel The electronic speedometer measures distance in miles and kilometers as well as hours of operation The speedometer also includes a reverse speed limit function that limits the ATV s speed in at approximately 7 to 9 mph Refer to page 43 for additional information To display each mode press the button on the face of the speedometer once to toggle through the functions Each function will be displayed as follows Miles 00000 0 M Trip Miles 000 0 M Hours 00000 0 H To reset Trip Miles 1 Toggle to Trip Miles 2 Hold down button approximately 4 seconds The speedometer also has additional features accessed through a sub menu These features are e Programmable service reminder based on hours e Programmable service reminder based on distance e Change distance measurement from Miles to Kilometers or vice versa Each service reminder is set to zero and must be programmed to activate the feature One or both service reminders can be set Whichever setting
103. pping Avoid turning at sharp angles in reverse Never open the throttle suddenly while backing Never activate override button while throttle is open Loss of control may result NOTE Most Polaris ATVs are equipped with a reverse speed limiter The override button should be used with caution as rearward vehicle speed is greatly increased Do not operate at wide open throttle Only open the throttle enough to maintain a desired speed Manual shift models Xpedition do not have a reverse speed limiter or an override ON BN CAUTION Opening the throttle more than required may cause excessive fuel to build in the exhaust resulting in engine popping and or engine damage 86 RIDING Safe Riding Tips Parking on an Incline Whenever the Vehicle is Parked 1 2 3 4 Turn the engine off Place the transmission in gear or in park Set the parking brake Avoid parking on an incline If it is necessary to park on an incline always block the rear wheels on the down hill side as shown above Shut off fuel supply AWARNING Indicates a potential hazard that could result in serious injury or death 87 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Careful periodic maintenance will help keep your vehicle in the safest most reliable condition Inspection adjustment and lubrication intervals of important components are explained in the following chart on the following pages Maintenanc
104. pplement that came with your machine 75 RIDING Pre Ride Inspection AWARNING You must inspect your ATV each time before riding to ensure it is in proper working order If proper inspection is not done severe injury or death could result Use the following checklist to verify your machine is in proper working order each time you ride Item Inspection Procedure 1 Tires check condition and pressures 2 Fuel and oil tanks fill both tanks to their proper levels 3 All brakes check operation adjustment and fluid level includes auxiliary brake 4 Throttle check for free operation and closing 5 Headlight Taillight Brakelight check operation of all indicator lights and switches 6 Engine stop switch check for proper function 7 Wheels check for tightness of wheel nuts and axle nuts check that axle nuts are secured by cotter pins 8 Drive chain condition and slack refer to drive chain adjustment Air cleaner element check for dirt clean or replace 10 Steering check for free operation noting any unusual looseness in any area 11 Loose parts visually inspect vehicle for any damaged components or loose nuts bolts or fasteners 12 Operators helmet goggles and clothing 13 Engine coolant Liquid Cooled Models Only check for proper level at the recovery bottle 76 RIDING Safe Riding Tips 1 Sit upright with both feet on the footrests and both hands on the handlebars 2 After st
105. que to 14 ft Ibs 1 93 kg m Add the correct amount of Polaris Premium Synthetic Gearcase Lubricant until oil reaches the bottom of the filler hole Check for leaks Reinstall propshaft shield or footwell and screws removed in step MAINTENANCE AND LUBRICATION Lubrication Transmission Lubrication Models with Dipstick Transmission Dipstick For most 2x4 models a transmission dipstick is located on the right side of the machine On the Sportsman the dipstick is located near the rear brake disc The transmission lubricant level should be checked monthly or 1000 miles 1600 km whichever comes first Transmission oil should be changed annually With the ATV on a level surface remove fill plug dipstick and check the lubricant level Lubricant should be kept at the full mark on the dipstick The correct transmission lubricant to use is Polaris Premium Synthetic Gearcase Lubricant PN 2871478 119 MAINTENANCE AND LUBRICATION Lu brication 2x4 Models To check the level 1 2 To change lubricant 1 2 gt 8 9 10 11 120 Remove fill dipstick and wipe clean Reinstall dipstick completely remove and check the level Add the proper lubricant as required to bring level into operating range as shown Remove skid plate if necessary Place a drain pan beneath the transmission oil drain plug area Loosen jam nut A Turn adjuster bolt B in to allow the
106. r s mixing recommendations for the freeze protection required in your area Using a funnel slowly add coolant as necessary through the radiator filler neck AWARNING Indicates a potential hazard that could result in serious injury or death 103 MAINTENANCE AND LUBRICATION Lubrication CAUTION Engine warranty coverage may become void if you use a brand other than Polaris in your machine Polaris 2 Cycle Lubricants Polaris has a family of premium oils available for use in all our products and highly recommends their use The only oils recommended for Polaris 2 cycle ATVs are Polaris Premium 2 cycle oil or Premium Gold Synthetic 2 cycle oil Polaris Premium 2 cycle lubricants are the most advanced formulation of oils specifically designed for today s 2 cycle engines Months of lab and field tests have resulted in a new generation of 2 cycle lubricants Polaris Premium 2 cycle lubricants provide additives for 2 cycle engines lacking in today s fuel that keep ring grooves cleaner for less ring sticking and provide improved overall engine cleanliness With new generation lubricity technology they excel in meeting the lubrication demands of today s high performance 2 cycle engines These are optimum oils recommended for liquid cooled and air cooled 2 cycle engines We believe these oils are the best available in the market today Premium Gold Synthetic 2 Cycle Oil Your vehicle has been primed with Premium Gold Synt
107. r machine before your ride Maximum grade while trailer towing 15 Do not tow any trailer on a grade steeper than 15 If your machine is equipped with a front rack take care when loading Improper loading of the front rack can obstruct the headlight beam reducing night visibility Do not obstruct the headlight beam with cargo Use of low forward gear is recommended in heavy pulling situations to extend belt life 72 OPERATION Carrying Loads AWARNING Correct loading of this vehicle is necessary to maintain proper stability and operating characteristics Overloading or incorrect positioning of the load affects the vehicle s turning stopping distance and stability Failure to follow loading requirements could cause severe injury or death 2 3 of Load o Rear Rack 1 3 of Load on Front Rack Important Safeguards To reduce risk of injury or machine damage when carrying loads read and follow the warnings listed below REDUCE SPEED AND ALLOW GREATER DISTANCE FOR BRAKING WHEN CARRYING CARGO CARGO WEIGHT DISTRIBUTION should be 1 3 on the front rack and 2 3 on the rear rack When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions Carrying loads on one rack only increases the possibility of vehicle tip over HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations which may
108. r maintained by the recovery system The recovery system components are the recovery bottle radiator filler neck radiator pressure cap and connecting hose As coolant operating temperature increases the expanding heated excess coolant is forced out of the radiator past the pressure cap and into the recovery bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the tank past the pressure cap and into the radiator NOTE Some coolant level drop on new machines is normal as the system is purging itself of trapped air Observe coolant levels and maintain as recommended by adding coolant to the recovery bottle Polaris recommends the use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water NOTE Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water NOTE Always follow the manufacturer s mixing recommendations for the freeze protection required in your area To access the recovery bottle on Gen IV machines B it is necessary to remove the left side panel as described on page 164 101 MAINTENANCE AND LUBRICATION Engine Cooling System AWARNING Never remove the pressure cap when the engine is warm or hot Escaping steam can cause severe burns The engine must be cool before removing the pressure cap Radiator Coolant Level Inspection NOTE This proce
109. rain Plug Torque 14 ft Ibs 19 Nm Oil Filter Torque Turn by hand until filter gasket contacts the sealing surface then turn an additional 1 2 turn 116 MAINTENANCE AND LUBRICATION Lubrication Transmission Lubrication Models with Fill Plug Scrambler 500 4x4 Xplorer 400 Xplorer 4x4 Magnum 500 Magnum 325 4x4 Magnum 325 2x4 The transmission fill plug is located on the right side of the machine behind the propshaft shield or footwell The transmission lubricant level should be checked every six months or 1000 miles 1600 km whichever comes first Transmission oil should be changed annually With the ATV on a level surface remove fill plug 1 and check the lubricant level Use the illustration and the chart below to determine the correct fluid level The correct transmission lubricant to use is Polaris Premium Synthetic Gearcase Lubricant PN 2871478 Oil Level A Oil Fill Ounces ml me 27 B00 117 Lu MAINTENANCE AND LUBRICATION brication Transmission Oil Changing Procedure 1 118 Remove the four screws on the footwell and gently pull outward for access Remove propshaft shield from the right side of the vehicle Scrambler 500 4x4 Xplorer 4x4 Remove fill plug Remove transmission drain plug located on the bottom left hand side and drain the oil refer to page 117 for the location of the Magnum drain plug Catch and discard used oil properly Clean and reinstall the drain plug tor
110. re refueling is performed or where gasoline is stored Do not over fill the tank Do not fill the tank neck If you get gasoline on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Gaso line powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time Shut off fuel valve whenever the ATV is stored or parked AWARNING The engine exhaust from this product con tains chemicals known to cause cancer birth defects or other reproductive harm 50 CONTROLS AND FEATURES Controls Engine Fuel and Oil System CAUTION On models with a two cycle engine use only Polaris injection oil Never substitute or mix oil brands Serious engine damage and voiding of warranty can result To avoid serious engine damage always top off the oil level when refueling On models with a two cycle engine the engine oil injection tank filler cap 2 is located on the front of the machine Refer to your Owner s Manual Supplement to determine the type of engine your vehicle has The tank capacity is 2 quarts 1 9 1 51 CONTROLS AND FEATURES Controls Automatic Transmission Gear Selector Shift patterns depend on the type of vehicle you own Please check your Owner s Manual Supplement to define your machine s shift pattern The transmission gear selector is located on the right
111. removal of drain plug C Remove the drain plug and wipe the magnetic end clean to remove accumulated metallic filings After the oil has drained completely install a new sealing washer and install the drain plug Torque to 14 ft Ibs 19 3 Nm Turn adjuster bolt B out until it touches the frame and then an additional 1 2 turn Tighten the jam nut securely while holding the adjuster bolt Add the proper lubricant through the dipstick hole until the oil level is between the upper and lower limits Do not overfill Check for leaks Reinstall skid plate if removed in step 1 MAINTENANCE AND LUBRICATION Lubrication Sportsman Transmission Oil Changing Procedure 1 Remove fill plug dipstick 2 Remove transmission drain plug side and drain the oil Catch and discard O used oil properly 3 Clean and reinstall the drain plug 4 Add 32 oz 948 ml Polaris Premium Synthetic Gearcase Lubricant PN 2871478 12 oz bottle to full mark on the fill plug dipstick Full 5 Check for leaks Operating Range 121 MAINTENANCE AND LUBRICATION Lubrication Front Gearcase Lubrication The front gearcase fill plug is located as shown The front gearcase lubricant level should be checked every six months or 1000 miles 1600 km whichever comes first Front gearcase oil should be changed annually Type A With the ATV on a level surface remove fill plug and check the lubricant level Lubricant should be kept at
112. rs or When Remarks Miles pa Ignition Timing 100hrs 12 Inspect and adjust as months needed Fuel System 100 12 Check for leaks at tank hours months cap lines fuel valve filter pump and carburetor Re place lines every two years fag Filter 100hrs 12 Replace annually months be 100hrs 12 Inspect clean external sur months face Cooling System 100 hrs 12 Inspect hoses months Spark arrestor 100 hrs 12 Clean out months Front hubs fluid 100 hrs 12 change AWD months Clutches drive and 100 hrs 12 Inspect clean driven months 92 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Item Hours or When Remarks Miles Engine Mounts 100 hrs 12 Inspect months E Valve Clearance 100 hrs 12 Inspect Adjust 4 Cycle months Injector Oil Filter 100 hrs 12 Replace 2 Cycle months Shift selector box H 200 hrs 24 Change lubricant every L R months two years Brake fluid 200hrs 24 Change every two years months Front wheel bearings 300 hrs 36 Inspect replace if neces 2wd months sary Idle Speed As Re As Re Adjust quired quired Recoil housing As re As re Drain moisture out after quired quired riding in water Toe adjustment As re As re Periodic inspection adjust quired quired when parts are replaced Headlight Aim As re As re Adjust if necessary quired quired 93 MAINTENANCE AND LUBRICATION Lubrication Recommendations iem Luber Method Fr
113. se the throttle each time you shift to the next lower gear 4 WARNING POTENTIAL HAZARD Shifting gears without releasing the throttle WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Always release the throttle when shifting gears 54 CONTROLS AND FEATURES Controls Shifting to Reverse With the ATV running and in neutral hold the brake lever and push the Reverse Override button on the LH control Depress the gear shift pedal one stroke The reverse indicator light will come on Slowly release the brake lever and press throttle control lightly AWARNING Be careful when operating in reverse Make certain your path is free of obstacles or and bystanders Risk of a tip over is greatly increased on hillS Avoid backing on hills or inclines whenever possible Tipovers could result causing severe injury or death Important Safeguards e Always back slowly avoiding excessive speed and do not use the reverse speed override switch system unless additional power is required for vehicle movement e Avoid turning at sharp angles in reverse e Avoid backing on steep inclines Light Switches and Indicator Lights AWARNING This ATV is not equipped with highway approved lighting This ATV is designed for off road use only and must not be ridden on streets or highways Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkne
114. snapped and unsnapped a few times 1 Remove seat Grasp rear of side panel near 1 rear cab With a quick and firm motion pull the panel forward and outward to disengage the two rear tabs 2 Place hand on top of side panel behind the fuel tank With a quick and firm motion push down on the side panel to disengage the top rear two tabs Then pull up on side panel to disengage front upper and lower tab 3 To reinstall side panel align panel tabs with slots on front cab Push panel upward and forward until tabs lock Bend rear of side panel and insert the two tabs into the rear cab 164 MAINTENANCE AND LUBRICATION Cleaning and Storage Cleaning Your ATV Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components With a few precautions your ATV can be cleaned much like an automobile Washing If a high pressure type car wash system is used extreme care must be taken to avoid water damage to the wheel bearings transmission seals body panels brakes and warning labels Many expensive repair bills can result from using high pressure detergent systems NOTE If a high pressure car wash is used grease all zerk fittings immediately after washing Also run the vehicle to evaporate any water that might have entered the engine or exhaust system The best and safest way to clean your ATV is with a garden hose and a pail of mild soap and water Use a professional t
115. ss 55 CONTROLS AND FEATURES Controls Shifting From Reverse to Forward Be sure machine is completely stopped Hold the brake lever raise gear shift pedal one full stroke to engage forward gear NOTE neutral is bypassed when shifting from reverse to 1st gear To engage neutral depress gear shift pedal one full stroke from the 1st gear position To Decelerate When slowing down or stopping release the throttle and apply the brakes smoothly and evenly As you slow down shift to a lower gear Be certain the engine has sufficiently slowed before engaging a lower gear Improper use of the brakes or shifting can cause the tires to lose traction reducing control and increasing the possibility of an accident 4 WARNING POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high WHAT CAN HAPPEN The wheels could stop rotating This could cause loss of control an accident and injury It could also cause engine or drive train damage HOW TO AVOID THE HAZARD Make certain the engine has sufficiently slowed before shifting to a lower gear 56 CONTROLS AND FEATURES Controls Recoil Starter If the battery is weak and cannot start the engine use of the recoil starter A located on the right side of the machine will allow vehicle operation until repairs can be made Polaris 4 cycle engines are equipped with automatic decompressors This makes recoil starting possible by allowing compression to l
116. ssible Causes Solutions What to do Loading the ATV into a pick Shift transmission to low range during up or tall trailer when in high loading of the ATV to prevent belt burn range ing Starting out going up a When starting out on an incline use steep incline low range or dismount the ATV after first applying the park brake and per form the K turn as described on page 83 of this manual Driving at low RPM or low Drive at higher speed or use Low ground speed at approxi Range The use of Low Range is high mately 3 7 MPH ly recommended for cooler PVT oper ating temperatures and longer compo nent life Insufficient warm up of Warm engine at least 5 min then with ATVs exposed to low ambi transmission in neutral advance ent temperatures throttle to approx 1 8 throttle in short bursts 5 to 7 times The belt will be come more flexible and prevent belt burning Slow and easy clutch en Fast effective use of the throttle for gagement efficient engagement Towing Pushing at low Use Low Range only RPM low ground speed Plowing snow dirt etc util Use Low Range only ity use Stuck in mud or snow Shift the transmission to Low Range carefully use fast aggressive throttle application to engage clutch WARN ING Excessive throttle may cause loss of control and vehicle overturn 169 TROUBLESHOOTING Climbing over large objects Shift the transmission to Low Range from a stopped positi
117. ssions warranty Please refer to your owner s manual supplement to determine if this applies to your vehicle Item Hours or When Remarks Miles Transmission Oil 20 hrs Monthly Inspect monthly change Level annually Battery 20 hrs Monthly Check Terminals clean check fluid level Engine Counterbal 20 hrs Monthly Check oil level change ance 400 Engines Engine breather filter 20 hrs Monthly Inspect replace annually 4 cycle and as needed Brake pad wear Monthly Inspect periodically Engine Cylinder 25 hrs 3 Inspect re torque required Head and months at first service only Cylinder Base Fas teners General Lubrication 50 hrs 3 Lubricate all fittings pivots months cables etc Engine Oil Level 100 hrs 6 Check Level Daily Break Change 4 Cycle 1000 months in Service at 1 month miles Change oil more often in cold weather use gt Front and Rear Gear 100 hrs Monthly Check monthly and case Oil shaft drive change annually gt 90 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Item Hours or When Remarks Miles A Oil Filter 4 Cycle 100 hrs 6 Replace with oil change Oil Pump Cable 50 hrs Inspect adjust lubricate 2 Cycle Pune replace if required Engine breather 100 hrs Inspect hose Shine 4 cycle Carburetor Float 50 hrs Drain bowl periodically and Bowl nie prior to storage Throttle Cable ETC 50 hrs Inspect adjust lubricate Switch ee
118. the bottom of fill plug thread The correct gearcase lubricant to use is GL5 80 90 Weight Gear Lube Type B The lubricant level in this type of gearcase cannot be checked You must periodically drain it and refill it according to the following procedure Gearcase Oil Changing Procedure 1 Remove fill plug 1 2 Remove gearcase drain plug located on the bottom right hand side and drain the oil 3 Clean and reinstall the drain plug and tighten securely 14 ft Ibs 1 93 kgm 4 Add 4 ounces 120 ml Type A or 5 ounces 150 ml Type B of GL5 80 90 Weight Gear Lube Visco lock C fill with the oil recommended by your owner s manual supplment until oil comes out the plug 5 Reinstall filler plug 6 Check for leaks 122 MAINTENANCE AND LUBRICATION Lubrication Rear Gearcase Lubrication With the ATV on a level surface remove fill plug and visually inspect the lubricant level through the fill hole 1 Lubricant should be kept even with the center of the drillpoint 2 approximately 1 5 8 below the top of the fill hole NOTE Do not add lubricant to the bottom of the fill plug threads The correct gearcase lubricant to use is GL5 80 90 Weight Gear Lube Oil Changing Procedure 1 Remove drain plug 3 Catch and discard used oil properly 2 Clean and reinstall the drain plug with a new sealing washer and tighten securely 14 ft Ibs 1 93 kgm 3 Remove fill plug and add 10 ounces 300 m
119. the button may be held to scroll through the digits from 0 to 9 5 After the digit has been selected do not push the button After 4 seconds the next digit will flash 62 CONTROLS AND FEATURES Features Electronic Speedometer Setting Service Hours cont 6 Repeat step 4 and 5 to program the digits for the service interval selected i e for service interval of 50 hours set the display to show 00050 H To save the changes press and hold the button when any one of the digits is flashing The display will change to DOnE At this time release the button and the changes are now saved TO CHECK WHEN SERVICE IS DUE BY HOURS Using the 50 hour service setting example from above the speedometer will take the 50 hour setting and add it to the value of the hour meter This will be the value displayed when the operator checks when service is due for the ATV For example the hour meter reading is 132 hours and the service interval was set for 50 hours the 5 digit display will show 182 hours 1 2 3 Access the sub menu Toggle to SET hr then release the button In 3 seconds the LCD will display 5 digits with the left most digit flashing As in the example above the display would show 00182 H Either turn the power off or not touch the button for 35 seconds to maintain the current settings 63 CONTROLS AND FEATURES Features Electronic Speedometer To Set Service Distance Same as setting Service Hours but t
120. the engine and occasionally during riding Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle lever The throttle lever 1 is spring loaded and engine speed returns to idle when the lever is released This vehicle is equipped with a Polaris Electronic Throttle Control ETC which is designed to reduce the risk of a frozen or stuck throttle In the event the throttle cable should stick in an open position the engine will stop and power to the rear wheels will cease when the operator releases the throttle lever Choke Refer to the engine starting procedure on page 70 for correct choke and throttle settings during starting 44 CONTROLS AND FEATURES Controls Brakes The front and rear brakes are applied by squeezing the left side brake lever toward the handlebar The front and rear brakes are hydraulically activated disc type brakes which are activated by one lever only Always test brake lever travel and reservoir fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before riding Contact your dealer for proper diagnosis and repairs AWARNING Never operate the ATV with a spongy feeling brake lever Operating the ATV with a spongy brake lever can result in loss of braking Loss of braking could cause an accident 45 CONTROLS AND FEATURES C
121. us engine damage 3 Start the engine and rotate the oil pump lever to its full open position With the engine at idle hold the lever up for thirty seconds to make sure all air is out of the system Throttle Cable Adjustment 250 and 400 Engines Vehicles with 250 and 400 engines do not utilize a cable sleeve jam nut You will need to bottom the cable to the carburetor slidevalve cap Adjust at throttle cable adjuster near the throttle block See page 137 for adjustment procedure Oil and Filter Change The recommended oil change interval is 100 hours 1000 miles or every six months whichever comes first Suggested break in oil change is at 20 hours 200 miles or one month whichever comes first Severe use operation requires more frequent service Severe use includes continuous duty in dusty or wet conditions and cold weather riding NOTE Severe use cold weather riding is all riding below 10 F and riding between 10 F and 30 F when most trips are slow speed and less than 5 miles Be sure to change the oil filter whenever changing oil 4 CAUTION Oil may be hot Do not allow hot oil to come into contact with skin as severe burns may result 108 MAINTENANCE AND LUBRICATION Lubrication Oil Filter and Change 4 Stroke models with an external oil tank 1 2 DN AE Place vehicle on a level surface Clean area around drain plug which is found at the bottom of the oil tank or on the bottom of the engine
122. ver run an engine in an enclosed area Carbon monoxide exhaust gas is poisonous and can cause severe injury or death Always start engines outdoors CAUTION You must allow your vehicle adequate warm up time before operating or engine damage could result 1 Place the transmission in neutral and reset the parking brake Turn the fuel tank valve to ON Sit on the vehicle Pull the choke out all the way Turn the engine stop switch to RUN 6 Turn the ignition key past the ON position to engage the starter Gr Genk NOTE the choke is on FULL when the knob is pulled out all the way The choke is OFF when the knob is pushed in This is a variable choke and can be adjusted gradually depending on how much choke is needed for starting 7 Do not press the throttle while starting the engine 8 Activate the starter for a maximum of five seconds releasing the Key or button when the vehicle starts If engine does not start release the starter and wait five seconds then activate the starter for another five seconds Repeat this procedure until engine starts 70 OPERATION Starting the Engine After the Engine Starts 1 Ifthe engine slows or stops use of the choke at half way in will allow proper engine warm up 2 Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly Then push the choke all the way in Cold Weather Operation 4 Cycle Engines Polaris
123. w 1 8 clearance and tighten retaining bolt to 5 ft Ibs 7Nm 11 Reinstall chain guards if removed NOTE Reposition chain guide to allow 1 8 3 cm clearance between sprocket and guide 90 144 MAINTENANCE AND LUBRICATION Adjustments Carburetor Adjustments If the vehicle is to be operated at various altitudes and temperatures certain adjustments can be made to improve its operation and driveability Above 6000 feet 1800 m the engine air fuel mixture becomes overly rich An engine loses approximately 3 of its power for each 1000 foot 304 8 m increase in elevation Although this power cannot be regained changes to the carburetor and drive system can be made to allow efficient operation These changes include 1 Carburetor re jetting to compensate for altitude and or temperature changes 2 Transmission convertor modification to adjust for engine horsepower loss during high altitude operation Contact your dealer 3 On 2 cycle models air screw adjustments can be made to compensate for temperature changes and or changes in altitude 4 On 4 cycle models pilot screw adjustments can be made to compensate for temperature changes and or changes in altitude NOTE Contact your dealer for altitude adjustments They have the training and special tools required to perform all necessary modifications for you Accessories There are a wide range of Polaris Accessories available for ATVs Contact your Polaris d
124. ype washing mitten cleaning the upper body first and the lower parts last Rinse with water frequently and dry with a chamois to prevent water spots NOTE If warning labels are damaged contact your a Polaris dealer for free replacement Waxing Your ATV can be waxed with any non abrasive automotive paste wax Avoid the use of harsh cleaners since they can scratch the body finish CAUTION Certain products including insect repellants and chemicals will damage plastic surfaces Care must be taken when using these products near plastic surfaces 165 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips CAUTION Do not start the engine during the storage period This will disturb the protective film created by fogging Cleaning Qutside Make necessary repairs and then clean the ATV thoroughly with a mild soap and warm water solution to remove all dirt and grime Don t use harsh detergents or high pressure washers Some detergents deteriorate rubber parts use dish soap type cleaners only High pressure washers may force water past seals Drain the recoil housing Stabilize Fuel Fill the fuel tank Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer Follow instructions on the container for recommended amount Carbon clean will also reduce the possibility of bacterial growth in the fuel system It s best to allow 15 20 minutes of operation for the stabilizer to disperse through the fuel in

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