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Univex Trail Blazer User's Manual

1. NOTE Ifthe engine is cold use the choke as outlined on page 47 4 Reach under the side panel and grasp the starter rope handle 2 firmly and pull slowly so you can feel the engine strokes NOTE Every other stroke will be a compression stroke and will make the rope harder to pull When a compression stroke is found continue pulling the rope just until the engine rolls past the stroke then stop pulling immediately 5 Allow the recoil rope to rewind into the recoil assembly then pull the rope abruptly and forcefully to start the engine 6 Repeat steps 4 5 if necessary CAUTION Extending the recoil starter rope until it stops can cause damage to the recoil assembly Do not extend the starter rope so far that it stops If the starter rope handle is not seated properly water may enter the recoil housing and damage components Make sure the handle is fully seated on the recoil housing especially when traveling in wet areas 43 OPERATION Break In Period The break in period for your new Polaris ATV is defined as the time it takes to use the first tank of fuel No single action on your part is as important as following the procedures for a proper break in Careful treatment of a new engine will result in more efficient performance and longer life for the engine Perform the following procedures carefully CAUTION Excessive heat build up during the first three hours of operation will damage clo
2. 57 OPERATION Driving Safely Driving Over Obstacles m Ah r Se IMAL Lh poa e y Fae Lan Ah KADA Be alert Look ahead and learn to read the terrain yov re traveling on Be constantly alert for hazards such as logs rocks and low hanging branches 4 WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle Not all obstacles are immediately visible Travel with caution in unfamiliar terrain 58 Driving Safely Driving in Reverse Follow these precautions when operating in reverse 1 Always avoid backing downhill 2 Back slowly 3 When in reverse apply the brakes lightly for stopping 4 Avoid turning at sharp angles in reverse 5 Never open the throttle suddenly while backing 4 WARNING OPERATION e Vlag DNS Ala Uea Z h ANAN WCO ye W Eie ANNU oe ss S e We 7 SAZA Failure to use caution when operating in reverse can result in serious injury or death Before shifting into reverse always check for obstacles or people behind the vehicle When it s safe to proceed back slowly Do not use the override switch unless additional power is required for vehicle movement Use with caution Avoid backing on inclines and avoid turning at sharp angles 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 incr
3. Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age Know Your Vehicle As the operator of the vehicle you are responsible for your personal safety the safety of others and the protection of our environment Read and understand your owner s manual which includes valuable information about all aspects of your vehicle including safe operating procedures Safety Training When you purchased your new ATV your dealer offered a hands on safety training course that covers all aspects of vehicle safety You were also provided with printed materials that explain safe operating procedures You should review this information on a regular basis If you purchased a used Polaris ATV from a party other than a Polaris dealer you can request this free safety training from any authorized Polaris dealer A Polaris ATV is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area We strongly advise you to strictly follow the recommended maintenance program outlined in your owner s manual This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your ATV Your safety is involved when these words and symbols are used Be
4. Drive belt 50 500 800 Inspect adjust replace as needed Engine oil change 100 H 1000 1600 Perform a break in oil change at one month ie 1000 1600 Replace with oil change 100 H cae 1000 1600 Inspect adjust Fuel system 100 H 1000 1600 Check for leaks at tank cap lines fuel valve filter pump carburetor replace lines every two years Fuel filter 100 H Ta 1000 1600 Replace yearly TR 7000 7600 Exhaust muffler 100 H 12M 1000 1600 Inspect pipe Spark plug 100 H 1 1000 1600 Inspect replace as needed Ignition Timing 100 H 1 1000 1600 1 1 Wiring 100 H 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc Clutches drive 100 H 1000 1600 Inspect clean replace worn and driven parts Front wheel 100 H 1 1000 1600 Inspect replace as needed bearings Oil filter change 100 H 6M 6M 6M 6M 6M 12M 12M 12M 2M 2M 2M 2M 2M 66 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Interval whichever comes first Calendar Miles Km Brake fluid 200 H 2000 3200 Change every two years Idle speed Adjust as needed Toe adjustment Inspect periodically adjust when parts are replaced Headightam Adjustas needed p Perform these procedures more often for vehicles subjected to severe use E Emission Control System Service California m Have an authorized Polaris dealer perform the
5. 7 Nm Reinstall the chain guard if applicable 85 MAINTENANCE AND LUBRICATION Filter Systems Air Filter Removal and Service Remove the ATV seat Release the clips securing the cover assembly to the air box Loosen the clamp securing the filter and remove the filter Remove the foam pre filter from the main filter Wash the pre filter in soapy water then rinse and let dry Re install the pre filter over the main filter Replace the main filter if needed Se ee Air Filter Installation 1 Check the condition of the air box and replace if necessary 2 Replace the filter over the carburetor boot Make sure the filter is fully seated in the air box 3 Tighten the clamp Do not overtighten as filter damage could occur 4 Check the cover gasket and replace if needed Be sure the cover is seated properly then snap the clips onto the cover 5 Reinstall the ATV seat Air Filter Cleaning Check and replace the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 65 NOTE Always replace the main filter when it becomes dirty In an emergency situation however you may clean the main filter if you observe the following practices 1 Never immerse the main filter in water Dirt can be transferred to the clean air side of the filter 2 If compressed air is used for cleaning never exceed a pressure of 40 PSI Always use a dispersion type nozzle to prevent filter damage and blow th
6. ANY OTHER CON TRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE Some states do not per mit 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 111 WARRANTY WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES 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 WARRAN TY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an im plied warranty lasts so the above limitation may not apply to you if inconsistent with con trolling state law HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service you must take it to a Polaris dealer authorized to re pair Polaris ATVs When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform war ranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate personnel at Polaris Th
7. Contact your dealer for proper diagnosis and repairs 4 WARNING Operating the ATV with a spongy brake lever can result in loss of braking which could cause an accident Never operate the ATV with a spongy feeling brake lever 36 FEATURES AND CONTROLS Parking Brake 4 WARNING Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death Always check to be sure the parking brake is disengaged before operating Setting the Parking Brake 1 Squeeze and release the brake 1 2 lever 1 two or three times then l squeeze and hold 3 Push the park brake lock 2 es forward to engage the brake FSA et Release the brake lever To release the parking brake lock squeeze and release the brake lever It will return to its unlocked position Important Safeguards The parking brake may relax if left on for a long period of time Al ways block the wheels to prevent rolling Always block the wheels on the downhill side of the ATV if leaving it parked on a hill Another option is to park the ATV in a sidehill position Never depend on the parking brake alone if the ATV is parked on a hill Always block the wheels to prevent rolling 37 FEATURES AND CONTROLS Auxiliary Brake WARNING Aggressively applying the rear brake when backing downhill may cause rear tipover which could result in serious injury or death Use caution when applyi
8. Install a one tooth smaller counter shaft sprocket RPM low ground speed Stuck in mud or snow Carefully use fast aggressive throttle application to en gage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large ob Carefully use fast brief aggressive throttle application to jects from a stopped posi engage clutch WARNING Excessive throttle may cause tion loss of control and vehicle overturn Belt slippage from water Dry out the PVT as outlined on page 95 Inspect clutch or snow ingestion into the seals for damage if repeated leaking occurs PVT system Clutch malfunction Contact your Polaris dealer for inspection of clutch com ponents Poor engine performance Check for fouled plugs or foreign material in gas tank fuel lines or carburetor Contact your dealer for service 107 TROUBLESHOOTING Contact your Polaris dealer for service if you re unable to identify solutions using the following charts Engine Doesn t Turn Over Possible Cause Solution Low battery voltage Recharge battery to 12 8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Engine Turns Over Fails to Start Possible Cause Solution Mechanical failure Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See y
9. Trail Bi en Ead Ees ea lt Owners Manu for Maintenance and MIRK gt POLARIS The Way Out Read this manual carefully It contains important safety information This is an adult vehicle only Operation is prohibited for those under 16 years of age 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 OR ALCOHOL PROTECTIVE GEAR NEVER 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 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 Part No 9919472 Rev 02 ec gt p hy PRINTED IN THE USA The Way Out A WARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm A card containing important ATV safety information should be attached to the owner s manual on the next page If you cannot locate this card or if it has been
10. a hill 61 OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 Turn the engine off 2 Place the transmission in gear 3 Set the parking brake 4 Always block the rear wheels on the downhill side See illustration 5 Shut off the fuel supply 62 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine intake or exhaust components as doing so may affect compliance with state and local noise level requirements Spark Arrestor Your Polaris vehicle has a spark arrestor that was tested and approved in accordance with the USDA Forest Service Standard 5100 1C Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 63 MAINTENANCE AND LUBRICATION Accessories Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights See your Polaris dealer Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest most reliable condition Inspection adjustment and lubrication of important components are explained in the periodic maintenance chart Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use genuine
11. equipped with highway approved lights It s designed for and must be used for off road use only Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness Light Switches The light switch is located on the left handlebar 1 It s used to turn a lt _ lt the lights on and off EA f Agee NOTE The lights won t work o unless the key is in the 1 ON position and the shut off switch is in the RUN position Indicator Lights With the engine running verify the function of all indicator lights each time the ATV is used NOTE The taillight is on whenever the main switch key is on Turn the key off to prevent battery drain 3 1 Transmission Neutral Indicator 2 Transmission Reverse Indicator 3 Oil Warning indicates a low oil level 34 FEATURES AND CONTROLS Brakes Check the brake fluid level in the master 1 cylinder before each use of the ATV The master cylinder 1 is located on the left handlebar 1 Position the ATV on level ground with the handlebars straight 2 View the fluid level through the indicator window 2 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 4 WARNING An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended
12. in a new area check for obstacles Avoid operating over large obstacles such as rocks and fallen trees when possible If unavoidable use extreme caution and always follow proper procedures as outlined in the owner s manual WARNING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Skidding or sliding can cause loss of control lf the tires regain traction unexpectedly the ATV could overturn HOW TO AVOID THE HAZARD On slippery surfaces such as ice travel slowly and use extra caution to reduce the chance of skidding or sliding out of control WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN The ATV could collide with an obstacle or person resulting in severe injury HOW TO AVOID THE HAZARD Before shifting into reverse gear always check for obstacles or people behind the ATV When it s safe to proceed back slowly SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Operating the 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 or overturn HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast flowing water If it s unavoidable to enter water that exceeds the recommended maximum depth see page 56 travel slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do n
13. level Do not overfill NOTE Under normal operation the diaphragm extends into the reservoir as fluid level drops If the fluid level is low and the diaphragm is not extended a leak is likely and the diaphragm should be replaced Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation We recommend the use of Polaris DOT 3 brake fluid Do not overfill 3 If the fluid level is low add DOT 3 brake fluid only See page 106 for the part numbers of Polaris products 4 WARNING Never store or use a partial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of accident or severe injury After opening a bottle of brake fluid always discard any unused portion 35 FEATURES AND CONTROLS Brake Lever The front and rear brakes are applied by squeezing the brake lever 1 toward the handlebar The front and rear brakes are hydraulically activated disc type brakes that are activated by only one lever Always test brake lever travel and master cylinder fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before riding
14. non recommended oil may cause serious engine damage We recommend the use of Polaris 2 cycle oils for your 2 cycle engine Never mix oil brands 70 MAINTENANCE AND LUBRICATION Lubrication Recommendations Engine Oil Check The oil tank cap 1 is located forward 1 of the headlight Check the oil before each use of the vehicle Refill the oil Lina when refueling s 1 Position the ATV on a level surface E ye 2 Remove the oil tank cap and f pE A inspect the oil level in the tank DRaa 3 Add oil as needed to bring the level to the full mark Do not overfill 4 Reinstall the oil tank cap 71 MAINTENANCE AND LUBRICATION Lubrication Recommendations Transmission Oil Check The transmission oil dipstick 1 is located 1 on the right side of the vehicle Check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 65 Maintain the transmission oil level in the SAFE operating range 2 We recommend the use of AGL Synthetic Gearcase Lubricant See page 106 for the part numbers of Polaris products 1 Position the ATV on a level surface 2 Remove the transmission oil dipstick and wipe it clean 3 Reinstall the dipstick then remove it and read the oil level If the level is low add the recommended gearcase oil to bring the level within the safe operating range on the dipstick 4 Reinstall the dipstick Transmission Oil
15. nuts that have a cotter pin installed See your Polaris dealer 2 Place the wheel on the wheel hub with the valve stem toward the outside and the rotation arrows on the tire pointing toward forward rotation 3 Install the wheel nuts and finger tighten On vehicles with tapered rear wheel nuts make sure the tapered ends of the nuts fit into the tapers on the wheels 4 Lower the vehicle to the ground 5 Torque the wheel nuts according to the wheel nut torque specifications chart Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loosened for maintenance service Item Specification Front Wheel Nuts 27 ft Ibs 86 5 Nm Rear Wheel Nuts 50 ft lbs 68 Nm 27 ft Ibs 36 5 Nm 81 MAINTENANCE AND LUBRICATION Adjustments Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations All service must be performed by your authorized Polaris dealer Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 cm or less See illustration 1 8 3 cm 4 WARNING Operating the vehicle with worn tires will increase the possibility of skidding which could lead to loss of control and serious injury or death Always replace tires when the tread depth measures 1 8 3 cm or less WARNING Use of non standard size or type of tires or improper tire inflation may adversely affect vehi
16. removed please call 1 800 342 3764 for assistance a b y 4 ig i O OO a ae a O gt Ss POLARIS For 50 years we ve been helping Polaris customers find The Way Out E a h bes a AA MO ee Par f q r A if adi Jind est EN PEN A o 4 re yt ne F O af It s been a fun ride But then after all these years That s what we re all about Find out more about our exciting once in a lifetime 50th Anniversary celebration Go to www polarisindustries com and look for the 50th Anniversary link This is a ride you don t want to miss POLARIS The Way Out Copyright 2004 Polaris Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited Printed in U S A 2005 Trail Blazer Owner s Manual P N 9919472 2 WELCOME Thank you for purchasing a Polaris vehicle and welcome to our world wide family of Polaris owners We proudly produce an exciting
17. through water 1 Determine water depths and current before crossing 2 Choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles if possible 4 After crossing dry the brakes by applying light pressure to the lever until braking action is normal After running the vehicle in water it s critical to have it serviced as outlined in the maintenance chart See page 64 The following areas need special attention engine oil transmission oil front and rear gearcases and all grease fittings 56 OPERATION Driving Safely Driving Through Water 4 CAUTION Major engine damage can result if the vehicle is not thoroughly inspected after operation in water Perform the services outlined in the maintenance chart If your vehicle becomes immersed or is operated in water that exceeds the footrest level take it to your dealer for service before starting the engine NOTE Avoid operating the vehicle through deep or fast flowing water If you cannot avoid water that exceeds the recommended maximum depth go slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes If your vehicle becomes immersed and it s impossible to take it to a dealer before starting it follow the steps described on page 91 Have the vehicle serviced by your dealer at the first opportunity
18. toe alignment of the vehicle The recommended toe alignment is 1 8 to 1 4 toe out dL te pO NOTE The steering frog can be Seo cy used as an indicator of ass whether the handlebars Sa Set the handlebars in a straight ahead position 2 Og A f A g a Or c Yh AN are straight The frog should always point straight back from the steering post Place stands 1 in front of the vehicle perpendicular to the rear tires See illustration Tie an elastic string around the stands making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in front of the vehicle 2 Measure the distance from 1 the string to the rim at the front and rear of the front rim 3 Rear measurement should be 1 16 1 8 2 to 3 cm more than the front measurement NOTE If you discover improper alignment see your Polaris dealer 76 for service MAINTENANCE AND LUBRICATION Adjustments Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts If loose nuts and bolts are found see your Polaris dealer for service before operating the vehicle Camber and Caster The camber and caster are non adjustable Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster 1 either clockwise or counterclockwise to increase or decrease spring tension NOTE Accessory sp
19. 1 OPERATION Driving Safely Driving Uphill Whenever traveling uphill follow these precautions 1 Always travel straight uphill 2 Avoid steep hills 25 maximum 3 Keep both feet on the footrests 4 Transfer your weight forward 5 Proceed at a steady rate of speed and throttle opening 6 Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle If all forward speed is lost 25 Maximum Keep your weight uphill Apply the single lever brake gradually When fully stopped apply the auxiliary brake as well then lock the park brake If the ATV begins rolling backwards Keep your weight uphill Never apply engine power Never apply the auxiliary rear brake while rolling backwards Apply the single lever brake gradually When fully stopped apply the auxiliary rear brake as well and then lock the parking brake Dismount on uphill side or to either side if ATV is pointed straight uphill Turn the ATV around and remount following the procedure described on page 55 WARNING Braking and handling are greatly affected when operating in hilly terrain Improper procedure could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 25 maximum Use extreme caution when operating on hills and follow proper operating procedures outlined in the owner s manual 52 OPERATION Driving Safely Sidehi
20. 1 2 turn CCW from seat Raise needle clip 1 position to lower jet needle 900 1800 3000 6000 Clutching Chart Altitude Shift Drive Clutch Driven Clutch Helix Spring Weight Spring Spring Setting Meters 0 1800 G Blue Green Red 40 Feet 0 6000 5630514 7041157 7041198 5131446 2 2 1800 3700 F Blue Green Red 40 6000 12000 5630515 7041157 7041198 5131446 2 2 105 POLARIS PRODUCTS Part No Description 2874438 2874439 2871460 2871312 2872073 2872348 2871326 2870990 106 TROUBLESHOOTING Drive Belt and Cover Problems Driving the ATV ontoa Avoid stopping on the ramp or creeping slowly up the pickup or tall trailer in ramp These practices may slip the clutch and belt high range Starting out going up a When starting out on an incline use low range or dis steep incline mount the ATV after first applying the park brake and perform the K turn as described on page 55 Driving at low RPM or Drive at a higher speed Avoid creeping low ground speed at approximately 3 7 MPH Insufficient warm up of Warm the engine at least 5 minutes With the transmission ATVs exposed to low am in neutral advance the throttle to about 1 8 throttle in bient temperatures short bursts 5 to 7 times The belt will become more flex ible and prevent belt burning Slow and easy clutch en Use the throttle quickly and effectively for efficient enga gagement gement Towing pushing at low
21. 7 Override Switch 52 P Parking Brake cic ct 4ce ayes tk os 37 Parking on an Incline 62 Periodic Maintenance Chart 64 67 POLARIS PRODUCTS 106 Pre Ride Inspection 46 PV CDinin evencieaisoweda ees 95 PY JS Y SIC eu bosch ato sere dees 94 95 R Rear Drive Chain Slack 84 85 Rear Spini ersan uada io Ay Recoil Housing 93 RECO Stal verssor oriri Tiia 43 S Safe Riding Gear 31 SAFETY are ae E 8 31 Safety Decals and Locations 28 30 Safety Training 8 Sideline srgere aneta eee 53 Spark AtrestOlis casyitvndeodwte 92 spark Plugs at tts ceed S ce 90 SPECIFICATIONS 103 105 Starting a Cold Engine 47 Starting a Warm Engine 48 Starting the Engine 47 48 Steering Assembly JI SOP OWC erana 8d erettaatete 32 Storage Hips Se ies Aes 100 102 T TABLE OF CONTENTS 5 Taillight Brakelight Lamp Replacement 89 Throttle Cable Freeplay 78 Throttle Levet recsss cs yates Ges 33 Tire Tread Depth nnnnnnn 82 Toe Alignment 76 Transmission Gear Selector 42 Transmission Oil Change 12 Transmission Oil Check J2 Transporting an ATV 102 TROUBLESHOOTING 107 110 Turning Around on a Hill 55 U USFS Approved Spark Arrestor 63 V VEHICLE IDENTIFICATION NUMBERS aaor 4 See we 7 Vehicle Immersi
22. ATURES AND CONTROLS WARNING Do not start or operate an ATV with sticking or improperly operating throttle controls which could cause an accident and lead to severe injury or death Always contact your dealer for service repairs if throttle problems arise Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation Always check the lever for free movement and return before starting the engine Also check occasionally during operation Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle lever The throttle lever 1 is spring loaded Engine speed returns to idle when the lever is released This ATV is equipped with Polaris 1 Electronic Throttle Control ETC which is designed to reduce the risk of a frozen or stuck throttle If the throttle cable should stick in an open position when the operator releases the throttle lever the engine will stop and power to the rear wheels will cease 4 WARNING 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 33 FEATURES AND CONTROLS WARNING Operating the ATV on streets or roads especially in darkness could result in an accident and serious injury or death Your ATV is not
23. Air Filter Air Box Inspect and clean or replace the pre cleaner and air filter Clean the air box and drain the sediment tube Recoil Housing Remove the recoil housing drain plug and drain any moisture Fluid Levels Inspect the following fluid levels and change if necessary engine oil transmission oil brake fluid change every two years or as needed if fluid looks dark or contaminated 100 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips See page 106 for the part numbers of Polaris products Engine Use Polaris Fogging Oil and follow the directions on the can 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 the spark plug Rotate the piston to BDC and pour approximately two ounces of the recommended oil into the cylinder Reinstall the spark plug 3 Apply dielectric grease to the inside of the spark plug cap and install the cap onto the plug 4 With the ignition off turn the engine over several times using the recoil starter This will ensure coverage of the piston rings cylinder walls and crankshaft bearings 5 Treat the fuel system with Polaris Carbon Clean 6 If Polaris fuel system additive is not used fuel tank fuel lines and carburetor should be completely drained of gasoline Lubricate Inspect all cables and lubricate with Polaris Cable Lubricant Foll
24. BS 348 kg Reduce speed and alow greater distance for braking when canying cargo Overloading or carrying tall off center or unsecured loads will increasa your risk of losing coniro Loads should be centered AW A R N l N G carried as low as possible and firmly secured to tha 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 toad extends over the side of the rack Moving parts hazard under belt clutch guard To Read Owner s Manual for more detailed loading information prevent serious injury do not operate vehicle 7172664 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 MONI a 28 SAFETY Safety Decals and Locations ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle s with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may se
25. Change 1 2 3 72 Place a drain pan beneath the transmission oil drain plug area Loosen the jam nut A Turn the adjuster bolt B in to allow the removal of the 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 reinstall the drain plug Torque to 14 ft Ibs 19 Nm mee Gace PSS He J Turn the adjuster bolt B out until it touches the frame and then turn an additional 1 2 turn Tighten the jam nut securely while holding the adjuster bolt Add the recommended lubricant through the dipstick hole until the oil level is between the upper and lower limits Do not overfill Check for leaks MAINTENANCE AND LUBRICATION Adjustments Oil Pump Bleeding Li CAUTION If the oil supply line has been disconnected from the pump or if the oil reservoir and supply line have been completely run out of oil the oil pump must be bled If the pump is not bled air in the lines may prevent oil delivery to the engine resulting in severe engine damage Fill the oil tank with the recommended oil See page 106 for the part numbers of Polaris products Loosen the bleeder screw one full turn Allow oil to flow from the bleed screw for five to ten seconds then tighten the bleed screw CAUTION Allowing the engine to run while the bleed screw is loose
26. DENTIFICATION NUMBERS 7 SAFELY saarra paeeedceahenesas 8 FEATURES AND CONTROLS 32 OPERATION 3433 6 io00a d bk oiid Tini ei 44 EMISSION CONTROL SYSTEMS 63 MAINTENANCE AND LUBRICATION 64 SPECIFICATIONS sudtueeeeddee eee eases 103 POLARIS PRODUCTS 000 00a 106 TROUBLESHOOTING s adeetascaauewnadads 107 WARRANTY 2 dctwt ee ei caiatee nw ota ea Stra wae 111 INDEX casictisey eaters detn i ick ea ay dean eee Ae 114 VEHICLE IDENTIFICATION NUMBERS Record your AT V s identification numbers and key number in the Spaces provided Remove the spare key and store it in a safe place Your key can be duplicated only by mating a Polaris key blank with one of your existing keys so if both keys are lost the ignition switch must be replaced Vehicle Model Number Frame VIN 1 Engine Serial Number right front side of engine crankcase Key Number 2 SAFETY Operator Safety 4 WARNING Failure to follow the warnings contained in this manual can result in serious injury or death A Polaris ATV is not a toy and can be hazardous to operate This vehicle handles differently than other vehicles such as motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions Read and understand your owner s manual and all warnings before operating a Polaris ATV
27. E 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 a greater distance for braking Always follow the instructions in the owner s manual for carrying cargo or pulling a trailer See page 60 WARNING POTENTIAL HAZARD Operating on frozen bodies of water WHAT CAN HAPPEN Severe injury or death can result if the ATV and or the operator fall through the ice HOW TO AVOID THE HAZARD Never operate the ATV on a frozen body of water SAFETY Operator Safety A A WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death Always remove the ignition key when the vehicle is not in use WARNING After any overturn or accident have a qualified service dealer inspect the entire vehicle for possible damage including but not limited to brakes throttle and steering systems 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 overturn and loss of control which could result in severe injury or death CAUTION Always keep combustible materials away from the exhaust system Exposure to the hot components could result in a fire 27 SAFETY Safety Decals and Locations Warning decals h
28. IMITED WARRANTY Polaris Sales Inc 2100 Highway 55 Medina MN 55340 gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle ATV against defects in material 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 war ranty period through a Polaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty THE PURCHASER MUST COMPLETEAN ATV SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE ATV No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your ATV is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void yo
29. NING Improper hill climbing procedures could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 25 maximum Use extreme caution when operating on hills and follow proper operating procedures outlined in the owner s manual If the vehicle stalls while climbing a hill never back it down the hill One maneuver that can be used when it s necessary to turn around while climbing a hill is the K turn 1 Stop and lock the parking brake while keeping body weight uphill 2 Leave transmission in forward and shut off the engine 3 Dismount on the uphill side of the vehicle or on the left if the vehicle is pointing straight uphill 4 Staying uphill of the vehicle turn the handlebars full left 5 While holding the brake lever release the parking brake lock and Slowly allow the vehicle to roll around to your right until it s pointing across the hill or slightly downward 6 Lock the parking brake and remount the vehicle from the uphill side keeping body weight uphill 7 Restart the engine with the transmission still in forward 8 Release the parking brake and proceed s owly controlling speed with the brake until the vehicle is on more level ground Uphill 55 OPERATION Driving Safely Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests 1 Follow these procedures when operating
30. PORTANT Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6 000 feet 1800 m and temperatures of 40 degrees F 4 degrees C or higher Above 6000 feet 1800 m the engine air fuel mixture becomes overly rich and the engine loses approximately 3 of its power for each 1000 foot 304 8 m increase in elevation Although this power cannot be regained adjustments to the carburetor and drive system can be made to allow more efficient operation Optional jets available from your Polaris dealer are required for operation above 6 000 feet and temperatures below 40 degrees F 4 degrees C NOTE Continuous operation of the engine without proper jetting when required can cause poor performance overheating or engine damage See your Polaris dealer for more information about jetting the ATV for conditions in your area If the engine idle speed is not satisfactory and all other conditions are favorable the carburetor can be adjusted 1 Warm up the engine by running the vehicle for approximately five minutes 2 Place the transmission in gear and lock the parking brake 3 Adjust the carburetor idle screw 1 either in or out until the desired idle RPM is reached Turn the screw in clockwise to raise RPM Turn the screw out counterclockwise to lower RPM 2 The following variations apply to air screw 2 adjustment for 2 cycle engines e For improving cold weather start and
31. Polaris parts available from your Polaris dealer NOTE Service and adjustments are critical If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently severe Use Definition e Frequent immersion in mud water or sand e Racing or race style high RPM use e Prolonged low speed heavy load operation e Extended idle e Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer Maintenance Chart Key gt Perform these procedures more frequently for vehicles subjected to severe use E Emission Control System Service California m Have an authorized Polaris dealer perform these services WARNING Improperly performing the procedures marked with a m could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services 64 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Perform all servic
32. actory Do not ever pry the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher 2 Ifthe voltage is less than 12 8 volts recharge the battery at 1 2 amps or less until the battery voltage is 12 8 or greater NOTE When using an automatic charger refer to the charger manufacturer s instructions for recharging When using a constant current charger use the following guidelines for recharging 4 WARNING An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging 97 MAINTENANCE AND LUBRICATION Battery Battery Charging NOTE Always verify battery condition before and 1 2 hours after the end of charging State of Charge Time Charge Using constant current charger standard amps specified on top of battery 100 12 8 13 0 volts None check at None required 3 mos from date of manufacture 75 100 12 5 12 8 volts May need slight 3 6 hours charge if no charge given check i
33. adlight beam should be aimed 8 20 3 cm below the mark placed on the wall NOTE Include rider weight on the seat when measuring gt 88 Adjust the beam to the desired position by turning the adjustment screws 1 Turning the right screw clockwise moves the intense spot of light up and to the left Turning the left screw clockwise moves the intense spot of the light up and to the right Turning the bottom screw clockwise adjusts the light upward MAINTENANCE AND LUBRICATION Lights Taillight Brakelight Lamp Replacement If the taillight brakelight does not work the lamp may need to be replaced 1 4 Remove the taillight lens cover mounting screws Remove the lens cover and gasket and set aside for reassembly Remove the lamp 1 Apply dielectric grease to the socket and install the new lamp Test the taillight brakelight to see that it s working Reinstall the gasket and lens cover Indicator Lamp Replacement i 2 3 Remove the instrument panel if necessary to access the back of the indicator panel Using a small straight blade screwdriver turn the base of the bulb 1 4 turn counterclockwise Using a needle nose plier or similar tool pull the lamp out of the indicator panel housing Insert the new bulb and seat it by turning it 1 4 turn clockwise Reassemble the pod or front cover 89 MAINTENANCE AND LUBRICATION Spark Plugs Always use the spark plugs recommended f
34. and streets e Never operate an ATV on a public street road or highway including a dirt or gravel road e Never operate an ATV without wearing an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots a long sleeved shirt or jacket and long pants e Never consume alcohol or drugs before or while operating an ATV e Never operate at excessive speeds Travel at speeds appropriate for the terrain visibility and operating conditions and your experience e Never attempt wheelies jumps or other stunts e Always inspect your ATV before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and schedules outlined in your owner s manual e Always keep both hands on the handlebars and both feet on the foot rests of the ATV during operation e Always travel slowly and use extra caution when operating on unfa miliar terrain Be alert to changing terrain conditions e Never operate on excessively rough slippery or loose terrain e Always follow proper turning procedures as described in this manu al Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speeds 10 SAFETY Operator Safety Always have the ATV inspected by an authorized Polaris dealer if it s been involved in an accident Never operate on hills too steep for the ATV or for your abilities Practice on smaller hills
35. ave been placed on the ATV for your protection Read and follow the instructions of the decals and other warnings on the ATV carefully If any of the decals shown in this manual differ from the decals on your ATV always read and follow the instructions of the decals on the ATV If any decal becomes illegible or comes off contact your Polaris dealer to purchase a replacement Replacement safety decals are provided by Polaris at no charge The part number is printed on the decal 4 WARNING eNever operate this vehicle on HILLS steeper than 25 degrees 25 To prevent flipover on hilly terrain when going up or down use throttle and brakes gradually eREVERSE operation can be dangerous even at low speeds Steering be comes difficult To prevent flipover avoid sudden braking or sharp turns eUse OVERRIDE for reverse speed limiter with caution To prevent loss of control never activate override button with open throttle ePARKING BRAKE may relax when used for more than 5 minutes When parking on grades leave shift in forward 7172665 4 amp WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH 7172566 4 amp WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE IN PSI KPa FRONT 4 27 6 REAR 3 20 7 MAXIMUM WEIGHT CAPACITY Gross Vehicle Weight INCLUDING MACHINE DRIVER AND CARGO IS 765 L
36. before attempting larger hills Always follow proper procedures for climbing hills Check the ter rain carefully before ascend a hill Never climb hills with excessive ly slippery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes Never go over the top of a hill at high speed Always follow proper procedures for going downhill and for braking on hills Check the terrain carefully before you start down a 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 Travel straight down the hill when pos sible Always follow proper procedures for crossing the side of a hill 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 ve mastered on level ground the turn ing technique outlined in this manual Avoid crossing the side of a steep hill when possible Always use proper procedures if you stall or roll backwards while climbing a hill To avoid stalling maintain a steady speed when climbing a hill If you stall or roll backwards follow the special pro cedure for braking described in this manual Always dismount on the uphill side or to either side if the ATV is pointed straight uphill Turn the ATV around and remount following the procedure de scribed in this manua
37. ce than the inside wheel when turning and the inside tire must slip traction slightly To make a 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 NOTE Practice making turns at slow speeds before attempting to turn at faster speeds 4 WARNING Turning at sharp angles or at excessive speeds can result in vehicle overturn and lead to serious injury Avoid turning at sharp angles Never turn at high speeds 50 OPERATION Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel or during freezing weather follow these precautions 1 Slow down when entering slippery areas 2 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 3 Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward 4 WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control accident and serious injury or death Never apply the brakes during a skid Do not operate on excessively slippery surfaces Always reduce speed and use additional caution 5
38. cessive clutch wear and damage may result If the ATV will be operated for extended periods below 5 MPH or for towing loads we recommend that you install a one tooth smaller counter shaft sprocket to raise the operating RPM far enough above the engagement RPM to reduce heat caused by incomplete engagement Reducing the temperature inside the clutch cover extends the life of the PVT components belt cover etc NOTE Avoid heavy pulling and extended low speed operation 94 MAINTENANCE AND LUBRICATION PVT System WARNING Failure to comply with the instructions in this warning can result in severe injury or death Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at a high speed The PVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures See your dealer as outlined in the owner s manual This PVT system is intended for use on Polaris products only Do not install it in any other product Always make sure the PVT housing is secure
39. charged can damage the battery and result in a shorter life It can also hinder vehicle performance Follow the battery charging instructions on page 97 before installing the battery 1 Ensure that the battery is fully charged Set the battery in the battery holder Connect and tighten the red positive cable first Connect and tighten the black negative cable last Reinstall the battery cover and attach the hold down strap Oe Gee Verify that cables are properly routed 96 MAINTENANCE AND LUBRICATION Battery Battery Storage Whenever the vehicle is not used for a period of three months or more remove the battery from the vehicle ensure that it s fully charged and store it out of the sun in a cool dry place Check battery voltage each month during storage and recharge as needed to maintain a full charge NOTE Battery charge can be maintained by using a 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 Battery Charging The following battery charging instructions apply only to the installation of a sealed battery Read all instructions before proceeding with the installation of this battery The sealed battery is already filled with electrolyte and has been sealed and fully charged at the f
40. cing the spark arrestor could result in serious injury or death Do not perform service on the spark arrestor while the system is hot Exhaust system temperatures can reach 1000 F Allow components to cool sufficiently before proceeding Remove any combustible materials from the area Wear eye protection and leather work gloves Do not stand behind or in front of the vehicle while purging Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas Never go under the vehicle while it s inclined Remove the arrestor clean out plug 1 from the bottom of the O muffler Place the transmission in neutral and start the engine P Q Purge carbon from the system by i momentarily revving the engine several times If carbon is expelled cover or plug the exhaust outlet 2 and rap on the pipe around the cleanout plug while revving the engine several more times If particles are still suspected to be in the muffler elevate the rear of the vehicle one foot higher than the front Set the parking brake and block the wheels Make sure the vehicle is in neutral and repeat steps 3 and 4 until no more particles are expelled when the engine is revved Stop the engine and allow the arrestor to cool Reinstall the arrestor plug and remove the outlet cover or plug MAINTENANCE AND LUBRICATION Recoil Housing To prevent possible engine damage always drain the recoil housing 1 after operating the ATV in very w
41. cle maneuverability and cause loss of control resulting in serious injury or death Maintain proper tire pressure as outlined in this owner s manual When replacing a tire always use original equipment size and type 82 MAINTENANCE AND LUBRICATION Adjustments Drive Chain Polaris ATV drive chains are equipped with o ring sealed permanently greased pins and rollers However the outer surfaces of the roller must be lubricated 1 Always inspect the drive chain prior to operating the vehicle Check for damaged or missing o rings or damaged rollers Check for correct slack adjustment ws Maintain the stone guard to rear sprocket clearance at 1 8 3 cm 4 Regularly lubricate the drive chain with Polaris chain lube or SAE 80 90 lube See page 106 for the part numbers of Polaris products CAUTION Washing the drive chain with a high pressure washer or gasoline can cause damage to the o rings causing premature wear and drive chain failure Don t use a high pressure washer or gasoline to clean the drive chain Cylinder Head Cylinder Base Fastener Have your dealer check the ATV cylinder head and cylinder base fasteners for proper torque at the first service or after 25 hours 83 MAINTENANCE AND LUBRICATION Adjustments Rear Drive Chain Slack CAUTION Adjusting or operating the ATV with improper rear drive chain slack can result in severe damage to the transmission and drive components Always make sure the slack is w
42. come familiar with their meanings before reading the manual A aA The safety alert symbol on your vehicle or in this manual alerts you to the potential for personal injury WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death CAUTION The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle NOTE A note will alert you to important information or instructions SAFETY Operator Safety 4 WARNING Serious injury or death can result if you do not follow these instructions and procedures which are outlined in further detail within your owner s manual e Read this manual and all labels carefully and follow the operating procedures described e Never operate an ATV without proper instruction Take a training course Beginners should receive training from a certified instructor Contact an authorized Polaris ATV dealer or call Polaris at 1 800 342 3764 to find out about the training courses nearest you e Never allow anyone under 16 years of age to operate this ATV e Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safe ty training course e Always avoid operating an ATV on paved surfaces including side walks driveways parking lots
43. d long pants P E A _ gt T 4 5 N S Vou DS DS 15 SAFETY Operator Safety WARNING 16 POTENTIAL HAZARD Operating the ATV after consuming alcohol or drugs WHAT CAN HAPPEN Consumption of alcohol and or drugs could seriously affect operator judgment Reaction time may be slower and operator balance and perception could be affected Consuming alcohol and or drugs before or while operating an ATV could result in an accident causing severe injury or death HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while operating an ATV WARNING POTENTIAL HAZARD Operating the ATV at excessive speeds WHAT CAN HAPPEN Excessive speed increases the operator s chance of losing control of the ATV which can result in an accident HOW TO AVOID THE HAZARD Always operate the ATV at a speed that s proper for the terrain visibility and operating conditions and your experience SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Attempting stunts increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt wheelies jumps or other stunts Avoid ae exhibition driving 4 WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident
44. different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Polaris Operators should 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 Severe injury and or death could occur if a child under the minimum age recommendation operates an ATV Even though a child may be within the recommended age group for operating some ATVs he she may not have the skills abilities or judgment needed to operate an ATV safely and could be susceptible to accident or injury HOW TO AVOID THE HAZARD No one under the age of 16 should operate a Polaris ATV 13 SAFETY Operator Safety WARNING 14 POTENTIAL HAZARD Carrying a passenger on an ATV WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator s ability to balance and control the ATV which could cause an accident lt 22 and injury to the er operator and or passenger HOW TO AVOID THE HAZARD Never carry a passenger The purpose of the long seat is to allow the operator to shift position as needed during operation It is not intended for carrying passengers WARNING POTENTIAL HAZARD Operatin
45. e extra caution when turning on any hill Avoid crossing the side of a steep hill 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 22 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Stalling rolling backwards or improperly dismounting while climbing a hill WHAT CAN HAPPEN The vehicle could overturn HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill lf all forward speed is lost Keep your weight uphill Apply the single lever brake gradually When fully stopped apply the auxiliary rear brake as well then lock the parking brake If the ATV begins rolling backwards Keep weight uphill Never apply engine power Never apply the auxiliary rear brake while rolling backwards Apply the single lever brake gradually When fully stopped apply the auxiliary rear brake as well and then lock the parking brake Dismount on uphill side or to either side if ATV is pointed straight uphill Turn the ATV around and remount following the procedure described in the owner s manual See page 55 23 SAFETY Operator Safety WARNING 24 POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn HOW TO AVOID THE HAZARD Before operating
46. e air from the inside to the outside 86 MAINTENANCE AND LUBRICATION Lights When servicing a halogen lamp don t touch the lamp with bare fingers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp WARNING Poor lighting while driving can result in severe injury or death Headlight and taillight lenses become dirty during normal operation Wash the headlights frequently to maintain lighting quality Hot components can cause serious burns to skin Do not service the headlamps until they ve cooled sufficiently Headlight Lamp Replacement if 2 3 Remove the front cover and unplug the light harness Remove the rubber cap from the back of the headlight to reveal the retention screw Remove the small phillips head screw and carefully remove the bulb from the housing Insert the new bulb into the housing and reinstall the retention screw Reinstall the rubber cap Reconnect the light harness and reinstall the cover Adjust the headlight aim if necessary 87 MAINTENANCE AND LUBRICATION Lights Headlight Adjustment i Position the vehicle on a level surface with the headlight approximately 25 ft 7 6 m from a flat 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 on the headlight Observe the headlight aim on the wall The most intense part of the he
47. e choke can cause the spark plug to become wet fouled 1 Position the vehicle on a level surface and place the transmission in neutral 2 Lock the parking brake turn the fuel tank valve to ON sit on the vehicle and turn the engine stop switch to RUN 3 Ifthe engine has cooled to a point where it does not readily start intermittent use of the choke pulled half way out may be necessary NOTE Ifthe engine is over choked when warm depress the throttle lever fully while cranking to aid in starting 4 Release the throttle lever immediately after the engine starts If the engine does not start and all conditions are favorable change the spark plug and try again 48 OPERATION Driving Safely Driving Procedures 1 Sit upright with both feet on the footrests and both hands on the handlebars 2 Start the engine and allow it to warm up then 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 Driveslowly Practice maneuvering and using the throttle and brakes on level surfaces 49 OPERATION Driving Safely Making Turns Your Polaris ATV is equipped with a solid rear axle that drives both rear wheels equally at all times This means that the wheel on the outside of the turn must travel a greater distan
48. e single brake lever toward the handlebar These brakes are self adjusting The following checks are recommended to keep the brake system in good operating condition Check more often if brakes are used heavily under normal operation such as operation in hilly country or in muddy terrain 1 Always maintain brake fluid level as recommended see page 35 2 Check the brake system for fluid leaks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness 5 Check the security and surface condition of the disc NOTE Install new brake pads when pads are worn to 3 64 1 cm 3 64 1 cm Auxiliary Brake The 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 footrest NOTE Since this is a rear brake only it will not be as effective as the all wheel single lever system The hydraulic auxiliary brake system requires no adjustment Always maintain the brake fluid level as recommended See page 38 15 MAINTENANCE AND LUBRICATION Adjustments 4 WARNING Severe injury or death can result from improper toe alignment and adjustment Do not attempt to adjust tie rod alignment All tie rod adjustments should be performed by an authorized Polaris dealer Toe Alignment Use the following procedure to check the
49. eased Do not operate at wide open throttle Open the throttle just enough to maintain a desired speed CAUTION Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust resulting in engine popping and or engine damage 59 OPERATION Hauling Cargo 2 3 1 3 Your ATV has been designed to carry or tow a certain amount of load if equipped with racks Always read and understand the load distribution warning labels on the vehicle and never exceed the weight capacities outlined in the specifications section of the owner s manual and on the safety decals Cargo weight should be evenly distributed 1 3 on the front rack and 2 3 on the rear rack and mounted as low as possible When operating over rough or hilly terrain reduce speed and cargo weight to maintain stable driving conditions Do not obstruct the headlight beam with cargo 60 OPERATION Hauling Cargo 4 WARNING Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability and result in serious injury or death Always follow these precautions when hauling Cargo e REDUCE SPEED AND ALLOW GREATER DISTANCE FOR BRAKING WHEN HAULING CARGO e 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 pos sibi
50. ectly below the handlebar Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Refer to the specifications section beginning on page 103 for capacities Fuel Filter Replace the in line fuel filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 65 Do not attempt to clean the fuel filter 39 FEATURES AND CONTROLS Fuel Safety 4 WARNING 40 Gasoline is highly flammable and explosive under certain conditions e Always exercise extreme caution whenever handling gasoline e Always refuel with the engine stopped and outdoors or in a well ventilated area e Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored e Do not overfill the tank Do not fill the tank neck e If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing e Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time e Turn the fuel valve off whenever the ATV is stored or parked WARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas FEATURES AND CONTROLS Oil Injection Tank CAUTION Mixing brands or using a non recommend
51. ed oil may cause serious engine damage We recommend the use of Polaris Premium Synthetic 2 cycle oil for your 2 cycle Polaris ATV Never substitute or mix oil brands To avoid serious engine damage always top off the oil level when refueling The oil injection tank filler cap 1 is located on the front of the vehicle Refer to the specifications section beginning on page 103 for capacities 41 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector 1 is located on the right side of the ATV F Forward F N Neutral R Reverse N R CAUTION Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage To change gears stop the vehicle and with the engine idling move the lever to the desired gear Whenever the ATV is left unattended always place the transmission in gear and lock the parking brake 42 FEATURES AND CONTROLS Recoil Starter If the battery has been drained or damaged and cannot start the engine use of the recoil starter 1 will allow vehicle operation until repairs can be made The recoil starter is located on the right side of the machine 1 Position the vehicle on a level surface and lock the parking brake see page 37 2 Shift the transmission into neutral 3 Make sure the engine stop switch is set to RUN and the main key switch is in the ON position
52. es at whichever maintenance interval is reached first Maintenance Interval whichever comes first Calendar Miles Km Pre Rid ed See Pre Ride Checklist Brake fluid level Brake lever travel Wheels fasteners Engine oil level al a Air filter pre filter ae as Inspect clean often i Drain deposits when visible Check operation Check operation apply dielectric grease if replacing Inspect replace as needed Drain water as needed Weekly check often if operating in Recoil housing Weekly wet conditions Brake pad wear Monthly 100 160 Inspect periodically Monthly 200 320 Check terminals clean test Transmission oil Monthly 250 400 Inspect level change yearly Engine breather 25 H Monthly 250 400 Inspect clean if needed filter if equipped General 5 3M 500 800 Lubricate all fittings pivots lubrication cables etc Air box sediment Daily tube Tail light Air filter main element 10H OH 65 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Interval whichever comes first Calendar Miles Km Carburetor float 500 800 Drain bowl periodically and bowl prior to storage 50 H iodi Throttle Cable 50 H 500 800 Inspect adjust lubricate ETC Switch replace if necessary Choke cable 50 H 500 800 Inspect adjust lubricate replace if necessary OH H l Carburetor air 5 500 800 Inspect ducts for proper intake ducts sealing air leaks flange
53. et conditions This should also be done before storing the ATV Water will enter the recoil housing if the starter handle is disengaged from the rope guide when under water The recoil handle must be behind the heat shield for it to seal properly The drain screw 1s located at the bottom of the recoil housing Use a wrench to remove the screw Be sure to reinstall the screw after draining the housing 93 MAINTENANCE AND LUBRICATION PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements As engine speed increases the force exerted on the movable drive sheave by the 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 This begins to occur at speeds of less than 5 MPH due to the system s dependence on engine speed For example when operating at a ground speed of 3 MPH the engine would be running at only about 1500 RPM with an engagement speed of about 1400 RPM Whenever operating this close to the engagement point the engine may be running at a speed too low to provide the adequate pinch needed to prevent incomplete engagement Incomplete engagement creates excessive heat that can destroy belts and clutch covers In some cases ex
54. g an ATV on paved surfaces including sidewalks paths parking lots and driveways WHAT CAN HAPPEN ATV tires are designed for off road use Operating on paved surfaces may seriously affect the handling and control of the ATV and could result in loss of control accident and or injury HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement If it s unavoidable travel slowly and avoid sudden turns or stops SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Operating this ATV on 7 public streets roads or i highways SS WHAT CAN HAPPEN x i The ATV could collide wy with another vehicle HOW TO AVOID THE HAZARD Never operate the ATV on any public street road or highway including dirt and gravel roads In many states it s illegal to operate ATVs on public streets roads and highways 4 WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet eye protection and protective clothing WHAT CAN HAPPEN Operating an ATV without an approved helmet increases the risk of a Ca severe head injury or J O J death in the event of an l E A a accident Operating without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket an
55. hrough Water 56 57 Driving Uphill stosy icndeuseies 52 E Electrical Switches 32 EMISSION CONTROL SYSTEMS 63 Engine Fogging 101 Engine Oil Check 71 Equipment Modifications 12 114 F FEATURES 23 cnawdcon ces 32 43 Filter Systems s503o4 4045 barasat 86 Front Wheel Hub Tightening 82 Fuel Piller s2udetcicteuse cc cose 39 Fuel sally gerran aa E 40 Fuel Stabilizer 100 Puech ank seod kee ai a sede ace anes 39 Fuel ValVe vn coerce aeee geese 39 G Gear SCleCOls 225 00nd cig gad 42 H Handlebar saen kare ase ate amen ase 4 78 Hauling Cargo 60 61 Headlight Adjustment 88 Headlight Lamp Replacement 87 l Indicator Lamp Replacement 89 Indicator Lights 34 J Jettie Chart s siessis ee teow eee 105 K KATUT sapie NEEN 55 L Light Switches esssnnaaa 34 DIG ING gt t aids oi dr tor pais eer eS 87 89 Lubricants 2 Cycle 70 Lubrication Recommendations 69 72 M Main Switch 32 MAINTENANCE AND LUBRICATION 64 102 Maintenance Record 68 Making Turns sso aru pteaiehew 50 N Noise Emission Control System 63 O COT TR AS ght A esha eases eget en 70 Oil Injection Tank 41 Oil Pump Adjustment 74 Oil Pump Bleeding 73 OPERATION 2 255 c0e0e003 44 62 Operator Safety 8 2
56. is warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Engine Oil 1 Mixing oil brands or using non recommended oil may cause engine damage We recom mend the use of Polaris engine oil 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty 112 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WAR RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCA TION This policy does not apply to vehicles that have received authorization for export from Polaris Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warranty or service bulletin coverage if you have any questions This policy does not apply to vehicles registered to government officials or military per sonnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Recalls How to Get Service In the Country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer If you move or are traveling within the country where your vehicle was purchased Warranty or Service Bu
57. ithin the stated specifications Check the amount of chain slack in three different locations by moving the vehicle slightly forward Measure the chain slack at the tightest of the three positions At this point the chain should have 3 16 3 8 48 cm 95 cm deflection Use the following procedure if adjustment is required lt Q pane Ga a DE ope 3 16 3 8 48 cm 95 cm da 1 Loosen the chain guide Loosen the two eccentric locking bolts 1 3 Loosen the caliper mounting bolt located on the left side of the swing arm 4 Insert a pin punch 2 through the sprocket hub and into the eccentric housing 84 MAINTENANCE AND LUBRICATION Adjustments Rear Drive Chain Slack i Roll the ATV forward or backward to adjust the chain slack to the proper tension See the illustration for proper splice link clip opening position 1 Tighten the eccentric locking bolts ia to 30 ft Ibs 41 Nm for machines eo without the hitch and 45 ft Ibs 61 Nm for machines with a hitch Tighten the caliper mount bolt to 15 ft Ibs 20 Nm Remove the pin punch Roll the ATV forward checking chain tension in several places around the chain NOTE The chain is adjusted correctly when the tightest portion of 6 7 the chain has approximately 3 8 10mm deflection Position the chain guide to allow 1 8 3mm clearance and tighten the retaining bolt to 5 ft Ibs
58. l Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as rocks or fallen trees Always follow proper procedures when operating over obstacles as described in this manual Always be careful of skidding or sliding On slippery surfaces like ice travel slowly and use extra caution to reduce the chance of skid ding or sliding out of control Avoid operating the ATV through deep or fast flowing water If it s unavoidable travel slowly balance your weight carefully avoid sud den movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes 11 SAFETY Operator Safety e Wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them lightly several times to allow friction to dry out the pads e Always check for obstacles or people behind the ATV before operat ing in reverse When it s safe to proceed in reverse move slowly and avoid turning at sharp angles e Always use the size and type of tires specified for your ATV and always maintain proper tire pressure e Never modify an ATV through improper installation or use of acces sories e Never exceed the stated load capacity for your ATV Cargo must be properly distributed and securely attached Reduce speed and follow the instructions in this manual for carrying cargo or towing Allow a greater di
59. l These necessary additives keep ring grooves cleaner for less ring sticking and improved overall engine cleanliness With new generation lubricity technology Polaris oils excel in meeting the lubrication demands of today s high performance 2 cycle engines We recommend the use of these optimum oils for Polaris liquid cooled or air cooled 2 cycle engines Polaris premium 2 cycle oils will mix with each other but consistent performance will be enhanced by selecting only one of the premium oils and maintaining regular use of that oil through the life of the unit Your dealer will be able to assist you with that selection based on your operating conditions and riding style Never mix Polaris premium 2 cycle oils with any other brand of oil including Polaris Nature Oil Biodegradable oil Their incompatibility could result in engine damage For best performance we recommend that you choose one oil for your ATV then continue to use it for the life of the unit See page 106 for the part numbers of Polaris products Polaris VES II Synthetic 2 Cycle Oil Your vehicle has been primed with VES II synthetic oil We recommend the continued use of this oil for your ATV This lubricant has been specially formulated for low smoke low odor low deposits and high lubricity Premium 2 Cycle Oil Polaris also has a TC W3 premium oil or Premium Gold Synthetic Oil suitable for use in all of our 2 cycle products CAUTION Mixing brands or using a
60. letin coverage of any kind Vehicles registered to Government offi cials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions call Polaris Customer Assistance United States 1 763 417 8650 Canada 1 204 925 7100 113 INDEX A PRCCESSOUICSS even dacs andes cope E A 64 Adjustments 73 85 Age Restrictions 0 8 Ait PET sce kG ae eal ees 86 Auxiliary Brake 38 75 B Battery eseye an awrite 96 98 Battery Charging 97 98 Battery Installation 96 Battery Removal 96 Battery Storage 97 102 Brake evel 7 oc a eenatre ene mN 36 Bid CS 25 7 a6 Gee anua Ge ne eles 35 75 Break In Period 44 45 C Camber and Caster FI CarDurclor a Vas vcdey Iai eee 79 COOKE paste ntshreia cg ete staat manatee 39 Chrome Wheel Care 102 Cleaning and Storage 99 102 Cleaning the ATV 99 Clutching Carts s2 5 4 0 sae gees 105 CONTROLES 2 opt raten na 32 43 Corrosion Removing 102 Cylinder Head Cylinder Base Fastener 83 D Drive Chaim 4s cxheuaes nere 83 Driving Downhill 54 Driving in Reverse 59 Driving on Slippery Surfaces 51 Driving Over Obstacles 58 Driving Procedures 49 Driving Safely 49 62 Driving T
61. line of utility and recreational products Polaris Recreational and Utility Vehicles e Snowmobiles e All terrain vehicles ATVs e Watercraft e Victory motorcycles e RANGER utility vehicles We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today Many years of experience have gone into the engineering design and development of your Polaris vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your service needs during and after the warranty period We also take great pride in our Parts Apparel and Accessories PAA products available through our online store at 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 LOCTITE is a registered trademark of LOCTITE Corporation TABLE OF CONTENTS WELCOME ce ne buna eeewta g eee een mea ards 3 VEHICLE I
62. lity of vehicle overturn e 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 operating condition When cargo loads are carried high on the racks the weight of the loads must be reduced to maintain stable operat ing conditions e ALL LOADS MUST BE SECURED BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle e OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be cen tered securely fasten load and operate with extra caution Al ways attach the tow load to the hitch point designated for your vehicle e HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing downhill e EXTREME CAUTION MUST BE USED when operating with loads extending over the rack sides Stability and maneuver ability may be adversely affected causing the machine to over turn e DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carry ing loads on the front rack e DO NOT TRAVEL FASTER THAN THE RECOMMENDED 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 towing loads in rough terrain while cornering or while ascending or descending
63. lletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to per form the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of the destination country before you move Vehicles importation rules vary considerably from country to country You may be required to present docu mentation of your move to Polaris Industries in order to continue your warranty cover age You may also be required to obtain documentation from Polaris Industries in order to register your vehicle in your new country How to Get Service If Purchased From A Private Party If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased all warranty coverage will be denied Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ranty or service bul
64. lling 4 WARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn resulting in severe injury or death Avoid crossing the side of a hill when possible Follow proper procedures as outlined in the owner s manual Sidehilling can be a dangerous type of driving and should be avoided if at all possible If you do enter into a situation where sidehilling is necessary follow these precautions 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 NOTE Ifthe vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately 53 OPERATION Driving Safely Driving Downhill aes A Ne AS Spe VK SRS Whenever descending a hill follow these precautions 1 Proceed directly downhill 2 Transfer your weight to the rear of the vehicle 3 Slow down 4 Apply the brakes slightly to aid in slowing using the single brake lever NOTE Familiarize yourself with operation of the auxiliary rear brake pedal for additional braking in the event of normal service brake loss WARNING Excessive speed can cause loss of control and lead to serious injury or death Always operate slowly when traveling downhill 54 OPERATION Driving Safely Turning Around on a Hill 4 WAR
65. ly in place during 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 1 Remove the drain plug and allow the water to drain Replace the drain plug 2 Start the engine and shift the transmission into neutral Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds 3 Allow the engine RPM to settle to idle speed then shift the transmission to the lowest available range 4 Test for belt slippage If the belt slips repeat the process 5 Take the vehicle to your dealer for service as soon as possible 95 MAINTENANCE AND LUBRICATION Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last Battery Removal 1 Disconnect the battery hold down strap and remove the battery cover 2 Disconnect the black negative battery cable first 3 Disconnect the red positive battery cable next 4 Lift the battery out of the ATV Battery Installation When installing a new battery make sure it s fully charged prior to its initial use Using a new battery that has not been fully
66. mm 1 103 SPECIFICATIONS 2005 Trail Blazer Drive System Drive System Type PVT Shift Type Side Lever F N R Gear Reduction Low Not Applicable 3 05 1 2 68 1 Not Applicable 11 36 76P Not Applicable 520 O Ring 23 x 7 10 4 psi 22 x 11 10 3 psi Suspension and Brakes McPherson Strut w 8 2 20 8 cm travel Progressive Rate w 10 5 26 7 cm travel CAM Hydraulic Disc Gear Reduction Reverse Gear Reduction Forward Front Drive ratio Final Drive ratio Center Drive ratio Drive Chain Front Tire Rear Tire Front Suspension Rear Suspension Shock Adjustment Front Brake Rear Brake Auxiliary Brake Park Brake Hydraulic Disc Hydraulic Disc Hydraulic lock all wheel Features 1 Single Beam 55 w 8 26 w 26 9 w 12V 14 AH Accessory Headlight Taillight Brake Light Battery DC Plug In Rear DC Socket Forward Electric Start High Temp Indicator Windshield Low Oil Light Neutral Indicator Accessory Standard Not Available Accessory Standard Standard Standard Accessory Standard Standard Reverse Indicator Speedometer Fuel Gauge Tool Kit 104 SPECIFICATIONS 2005 Trail Blazer Jetting Chart Altitude Ambient Below 0 F 0 to 40 F 40 to 80 F 80 F amp Above Temperature Below 18 C 18 C to 5 C to 26 C amp 5 C 26 C Above Meters 0 900 Feet 0 3000 z 1800 2700 6000 9000 2700 3700 9000 12000 Turn air screw out
67. n 3 months 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with At least 20 hours desulfating charger 98 MAINTENANCE AND LUBRICATION Cleaning and Storage See page 106 for the part numbers of Polaris products Cleaning the 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 the ATV The best and safest way to clean your ATV is with a garden hose and a pail of mild soap and water Use a professional type washing mitten cleaning the upper body first and the lower parts last Rinse with water frequently and dry with a chamois to prevent water spots NOTE If warning and safety labels are damaged contact your a Polaris dealer for free replacement Polaris does not recommend the use of a high pressure type car wash system for washing the ATV If a high pressure system is used exercise extreme care to avoid water damage to the wheel bearings transmission seals body panels brakes warning labels and decals NOTE Grease all zerk fittings immediately after washing and allow the vehicle to run for a while to evaporate any water that may have entered the engine or exhaust system Waxing the ATV Your ATV can be waxed with any non abrasive automotive paste wax Av
68. ng the auxiliary brake Do not aggressively apply the auxiliary brake when going forward The rear wheels may skid and slide sideways causing loss of control and serious injury or death The auxiliary brake 1 is located on the inside of the right floor board and is operated by the right foot The auxiliary brake serves as a backup to the main brake system if the main system becomes inoperative If the rear wheels slide while using the auxiliary brake reduce brake pedal pressure to brake the rear wheels without skidding Check the brake fluid level frequently for the auxiliary brake system The reservoir is located under the seat or near the foot brake Maintain the fluid level between the maximum and minimum marks 38 FEATURES AND CONTROLS Choke The choke assists in starting a cold engine Refer to the engine starting procedure on page 47 for correct choke and throttle settings during starting Fuel Valve The fuel valve 1 is located on the left side of the vehicle below the fender It has three positions OFF For vehicle storage and when transporting ON For normal operation RES For reserve supply if main supply is exhausted NOTE There s about a 7 to 10 mile 11 2 reserve gas Always refill the gas after using the reserve supply Always return valve to ON position after refueling Fuel Tank The fuel tank filler cap 2 is located dir
69. oid the use of harsh cleaners since they can scratch the body finish CAUTION Certain products including insect repellants and chemicals will damage plastic surfaces Use caution when using these products near plastic surfaces 99 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips See page 106 for the part numbers of Polaris products CAUTION Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur Never start the engine during the storage period Exterior Make necessary repairs and then clean the ATV thoroughly with mild soap and warm water 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 Fuel Stabilizer Polaris Carbon Clean is a fuel stabilizer and fuel system dryer It cleans the fuel system the combustion chamber and the exhaust ports It also prevents bacterial growth and promotes better starting after the storage period 1 Fill the fuel tank with fuel and add Polaris Carbon Clean or Fuel Stabilizer Follow the instructions on the container for the recommended amounts 2 Start the engine and allow it to run for 15 20 minutes so the stabilizer can disperse through the fuel in the tank and carburetor 3 Stop the engine turn the fuel valve off and drain the carburetor bowl
70. on 91 W WARRANTY 111 113 Washing the ATV 99 Waxing the ATV 99 WELCOMES za ris penae eed 3 3 Wheel Installation 81 Wheel Nut Torque Specifications 81 Wheel Removal 80 115
71. or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the owner s manual 17 SAFETY Operator Safety WARNING 18 POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation WHAT CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV If the operator s foot is not firmly planted on the footrest it could come Into contact with the rear wheels and lead to accident or injury HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation WARNING POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or 7 a S amp S overturn athe en ab vas A HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough slippery or loose terrain WHAT CAN HAPPEN Operating on excessively rough slippery
72. or loose terrain could cause loss of traction or loss of control which could result in an accident or overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you ve learned and practiced the skills necessary to control the ATV on such terrain Always use extra caution on rough slippery or loose terrain 4 WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner s manual Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speed 19 SAFETY Operator Safety 4 WARNING 20 POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle may overturn HOW TO AVOID THE HAZARD Never operate on hills too steep for the ATV or for your abilities Never operate the ATV on hills steeper than 25 Practice on smaller hills before attempting large hills WARNING POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner s manual Ar es Always check the terrain een carefully before ascending a any hill Never operate the ATV on hills stee
73. or your ATV Refer to the specifications section beginning on page 103 for the recommended spark plug type and gap CAUTION Using non recommended spark plugs can result in serious engine damage Always use Polaris recommended spark plugs Spark plug condition is indicative of engine operation The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color 4 WARNING A hot exhaust system and engine can cause serious burns Wear protective gloves when removing a spark plug for inspection 1 Normal The normal 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 wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended injection oil improper use of the choke or incorrect carburetion adjustments Spark Plug Removal and Replacement 1 Remove the spark plug cap 2 Using the special wrench provided in the tool pouch ro
74. ot make sudden throttle changes Wet brakes may have reduced stopping ability Always test the brakes after leaving water If necessary apply them several times to let friction dry out the pads 4 WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires or operation of the ATV with improper or uneven tire pressure could cause loss of control or accident HOW TO AVOID THE HAZARD Always use the size and type of tires specified for the ATV Always maintain proper tire pressure as specified 25 SAFETY Operator Safety WARNING 26 POTENTIAL HAZARD Operating the ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of the ATV may cause changes in handling which could lead to an accident HOW TO AVOID THE HAZARD Never modify the ATV through improper installation or use of accessories All parts and accessories added to the vehicle must be genuine Polaris Industries Inc or equivalent components designed for use on this ATV and should be installed and used according to approved instructions See your authorized Polaris ATV dealer for more information WARNING POTENTIAL HAZARD Overloading the ATV or carrying towing cargo improperly WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling which could lead to loss of control or an accident HOW TO AVOID TH
75. our Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs 108 TROUBLESHOOTING Engine Backfires Possible Cause Solution Weak spark from spark plugs Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Runs Irregularly Stalls or Misfires Possible Weak Spark Cause Solution Possible Lean Fuel Mixture Cause Solution Possible Rich Fuel Mixture Cause Solution 109 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Turn fuel valve to reserve refuel Kinked or plugged fuel vent line Inspect and replace Water present in fuel Replace with new fuel Overuse of choke Inspect clean and or replace spark plugs Fouled or defective spark plugs Inspect clean and or replace spark plugs Worn or defective spark plug wires See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Low battery voltage Recharge battery to 12 8 VDC Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your Polaris dealer Electronic throttle control malfunction See your Polaris dealer Other mechanical failure See your Polaris dealer Overheated engine Clean engine exterior See your Polaris dealer 110 WARRANTY L
76. ow 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 Battery Storage Remove the battery from the vehicle and ensure that it s fully charged before placing it in storage See page 97 for instructions Storage Area Covers Set the tire pressure and safely support the ATV with the tires 1 2 off the ground Be sure the storage area is well ventilated and cover the machine with a genuine Polaris ATV cover NOTE Do not use plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation 101 MAINTENANCE AND LUBRICATION Cleaning and Storage Chrome Wheel Care if equipped Proper maintenance will protect chrome wheels from corrosion preserve wheel life and ensure a like new appearance for many years 1 Wash chrome rims frequently Use a mild detergent to remove any salt dirt mud or grime Never use abrasive cleaners on plated or painted surfaces 2 Polish the clean chrome wheels periodically Use an automotive grade chrome polish 3 Routinely and liberally apply a weather resistant wax to each polished chrome wheel Choose a product suitable for chrome finishes Read and follow the product labels and instructions 4 Chrome wheels exposed to road salt or salt in the ai
77. p for several minutes before operating the vehicle 1 Place the transmission in neutral and lock the parking brake Make sure the fuel valve is on 2 Sit on the vehicle and pull the choke knob 1 out until it stops NOTE Ifthe knob doesn t stay where positioned increase the tension by rotating the tension adjusting nut 2 clockwise NOTE The variable choke is fully on when the knob is pulled completely out The choke is off when the knob is pushed completely in The choke can be adjusted gradually depending on how much choke is needed for starting Be sure the choke is off during Operation as excess fuel washing into the engine oil will increase wear on engine components 3 Move the engine stop switch to RUN NOTE Do not press the throttle while starting the engine 4 Turn the ignition key past the ON position to engage the starter for a maximum of five seconds Release the key when the engine starts If it doesn t start release the key and wait five seconds Activate the starter for another five seconds Repeat until the engine starts 5 If the engine slows or stops position the choke knob half way in to allow proper engine warm up 6 Vary the engine RPM slightly with the throttle to aid in warm up When the engine idles smoothly push the choke all the way in 47 OPERATION Starting the Engine Starting a Warm Engine Warm engines do not normally require the use of the choke Excessive use of th
78. pants with kneepads and a jersey with shoulder pads provide the best protection 31 FEATURES AND CONTROLS Electrical Switches L 4 WARNING Activating the override switch while the throttle is open can cause loss of control resulting in severe injury or death Do not activate the override switch while the throttle is open Override Switch 1 Reverse Speed Limiter This vehicle is equipped with a reverse speed limiter system To gain additional power while Vee backing depress the override switch Main Switch 2 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 OFF RUN OFF NOTE Turning off the main switch will shut off all electrical power to the vehicle including the lights 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 Engine Stop Switch 3 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 an emergency To stop the engine slide the stop switch either right or left to the OFF position NOTE Turning off the engine stop switch will shut off all electrical power to the vehicle including the lights 32 FE
79. per than 25 Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly while traveling uphill 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 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Traveling downhill improperly WHAT CAN HAPPEN Improperly descending a hill could cause loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner s manual NOTE A special technique or is required when braking yo ea while traveling downhill See page 54 Always check the terrain carefully before descending a hill Shift your weight backward Never travel down a hill at high speed Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when possible 21 SAFETY Operator Safety WARNING POTENTIAL HAZARD eae Improperly crossing hills and eS ae turning on hills WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of control or overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 55 Us
80. r in coastal areas are more susceptible to corrosion if not properly cleaned Clean chrome wheels more often if they re exposed to salt or other corrosive elements Removing Corrosion If light rust is found on the chrome finish use steel wool 0000 OTT grade to remove it Gently rub the affected areas with the steel wool until the corrosion has been removed Clean and polish the wheel as outlined above Transporting an ATV Follow these procedures when transporting an ATV 1 Turn off the engine and remove the key to prevent loss during transporting 2 Turn the fuel valve off 3 Be sure the fuel cap oil cap and seat are installed correctly and securely 4 Always tie the frame of the ATV to the transporting unit securely using Suitable straps or rope The rack bumper or handlebars do not offer enough support for tie down while transporting the unit gt X 2 ATN ee if SB a 5 Always place the transmission in gear FW RS i 1 AS AT he YA and lock the parking brake l U y CAL Y lt I j E f ots at R A 102 SPECIFICATIONS 2005 Trail Blazer Body Si Gross Vehicle Weigh Fuel Capacity Engine Oi Transmission Oi Maximum Capacity Rear Rack Accessory Tongue Weight Tow Hich Tow Capacity Torn Radius Ground Clearance High Longin Seat Hei Wheel Bas Width Engine Cooling 150 wats G 4000 RPM TIVNBOSS 150 ex Timing 25 3 3000 Spark Plug Type Gap NGK BRS8ES 028 in 7
81. reducing audible detonation noise the air screw can be closed from 1 2 to 1 turn by turning the screw clockwise e During hot weather and or high altitude operation the air screw can be adjusted for smoother operation by turning the screw counter clockwise for approximately 2 turns 79 MAINTENANCE AND LUBRICATION Adjustments WARNING Operating your ATV with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death Maintain proper tire pressure as described on the decal on your ATV and in your owner s manual Always use original equipment size and type when replacing tires Make sure the wheels are installed properly Always replace tires when the tread depth measures 1 8 3 cm or less Wheel Removal 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 80 MAINTENANCE AND LUBRICATION Adjustments Wheel Installation 1 Place the transmission in gear and lock the parking brake WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Always ensure that all nuts are torqued to specification Do not service axle
82. rings are available through your Polaris dealer Tf MAINTENANCE AND LUBRICATION Adjustments 4 WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars resulting in loss of control and possible serious personal injury or death Follow the adjustment procedures exactly or see your Polaris dealer for service Handlebars The handlebars can be adjusted for rider preference 1 Remove the handlebar cover and locate handlebar bolts 1 2 Loosen the four bolts 3 Adjust the handlebar to the desired height Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right 4 Torque the front two bolts to 10 12 ft Ibs 14 17 Nm then torque the rear two bolts A gap of up to 1 8 will remain at the rear bolts Throttle Cable Freeplay Throttle cable freeplay is adjusted at the handlebar 1 Slide the boots 1 off the inline cable adjuster sleeve 2 Loosen the adjuster locknut 3 2 Turn the adjuster until 1 16 to 1 8 freeplay is achieved at the thumb lever NOTE While adjusting freeplay be sure to flip the throttle lever back and forth 3 Tighten the locknut and slide the boots over the cable adjuster until they touch at the midpoint of the adjuster 1 2 3 1 ce 78 MAINTENANCE AND LUBRICATION Adjustments Carburetor IM
83. riously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS IF OWNER S MANUAL IS MISSING CONTACT A POLARIS DEALER FOR A REPLACEMENT 1997 2000 7172560 29 SAFETY Safety Decals and Locations A WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death NEVER operate this ATV if you are under age 16 7172559 Under Seat Operation of this ATTENTION Specific carburetor jetting vehicle without the and adjustments are filter element will severely required depending on temperature damage the engine and altitude See your Owner s Manual RH S A Clean air filter often more Factory setting WI ngarm frequent cleaning required 40 to 80 F at 0 3000 feet 5 to 27 i itions ato ters Chain Freeplay Is Important in dusty conditions G at 0 900 meters 7079901 Adjust Froepley to 3 16 3 8 DO NOT Overtension See Owner s Manual Torque Nut on Eccentric Bolts To 30 Ft Lbs For models without a hitch To 40 Ft Lbs For models with A MON 7078572 MANUFACTURED BY POLARIS IND INC DATE OVERRIDE VIN SWITCH THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT Reverse Speed is INTENDED FOR USE ON PUBLIC ROADS limited CE V HICULE EST UN V HICULE TOUT TERRAIN QUI N EST Reverse override is PAS DESTIN TRE UTILIS SUR LES CHEMINS PUBLICS controlled b
84. se fitted engine parts Do not operate at full throttle or high speeds for extended periods during the first three hours of use Use of any oils other than those recommended by Polaris may cause serious engine damage We recommend the use of Polaris 2 cycle oil for your 2 cycle engine Lack of proper lubrication will cause serious engine damage Always fill the oil tank when refueling the ATV 44 OPERATION Break In Period The first tank of fuel must be pre mixed according to the following instructions After the break in period the oil injection system will provide the necessary engine lubrication without pre mixing 1 2 a 4 Premix the recommended oil with gasoline in a suitable gas container Refer to the chart below for ratios Fill the fuel tank see page 39 then fill the oil tank with the recommended oil Drive slowly at first Vary the throttle positions Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist on page 46 After the first tank of pre mixed fuel has been used 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 Fuel Oil Premix Chart Fuel Oil 40 1 Gallons Liters Ounces Liters 1 3 8 3 2 09 5 18 9 16 47 10 37 9 32 95 45 OPERATION Pre Ride In
85. se services 67 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance Maintenance Interval Performed 68 MAINTENANCE AND LUBRICATION Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 65 Lubrication Chart Key gt More often under severe use such as wet or dusty conditions Polaris Premium All Season Grease or grease conforming to NLG No 2 such as Conoco Superlube M or Mobilegrease Special a a Polaris Injection Oil Fill oil tank See page 41 DOT 3 fluid only Maintain level between fill lines See page 35 Drive chain s O ring chain lube or Lubricate as often as required Before SAE 80 90 each ride in wet conditions Transmission AGL Synthetic Gear See Page 72 case Lube 1 Ball Joint x Grease Locate fitting on back side of struts and grease with grease gun 1 2 2 Swing Arm x Grease Locate fittings on swing arm and grease Bushings with grease gun 3 Axle Housing px Grease Locate fittings on swing arm and grease with grease gun 69 MAINTENANCE AND LUBRICATION Lubrication Recommendations Polaris 2 Cycle Lubricants Polaris Premium 2 cycle lubricants are the most advanced formulation of oils specifically designed for today s 2 cycle engines These lubricants provide additives for 2 cycle engines that are lacking in today s fue
86. spection 4 WARNING lf a proper inspection is not done before each use severe injury or death could result Always inspect the vehicle before each use to ensure it s in proper operating condition Pre Ride Checklist Ensure proper operation Brake system lever travel Ensure proper operation 36 75 Brake fu Ranliany bral Font evepersi Rear auspensa Stet Wheels fasteners 81 Frame nuts bolts fasteners Tires Fuel and oil Ensure proper levels 71 Coolant level if applicable Ensure proper level Coolant hoses if applicable Inspect for leaks Ensure proper operation gt x O ot D ndicator lights switches Engine stop switch Ensure proper operation Drive chain Check condition slack lubricate as 85 needed Air filter pre filter Inspect clean Air box sediment tube Drain deposits whenever visible 87 Headlamp Check operation Brake light tail lamp Check operation apply Polaris dielec tric grease when lamp is replaced Riding gear Wear helmet goggles protective 31 clothing oo U Ge co ols Go Oo t N SJN l oO Co ec D 46 OPERATION Starting the Engine Starting a Cold Engine WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death Never run an engine in an enclosed area CAUTION Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm u
87. stance for braking e Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting FOR MORE INFORMATION ABOUT ATV SAFETY call the Con sumer Product Safety Commission at 1 800 638 2772 or call Polaris at 1 800 342 3764 Equipment Modifications We are concerned for the safety of our customers and for the general public Therefore we strongly recommend that consumers do not install on a Polaris ATV any equipment that may 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 vehicle create a substantial safety hazard and increase the risk of bodily injury The warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power 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 vehicle Use only Polaris approved accessories and familiarize yourself with their function and effect on the vehicle 12 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Operating this ATV without proper instruction WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on
88. tate the spark plug counterclockwise to remove 3 Reverse the procedure for spark plug installation Torque to 14 ft Ibs 19 Nm 90 MAINTENANCE AND LUBRICATION Vehicle Immersion CAUTION If your vehicle becomes immersed major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine If it s impossible to take your ATV to a dealer before starting it follow the steps outlined below de a ike ae 8 9 10 11 i 13 Move the ATV to dry land or at the very least to water below the foot rests Check the airbox for any water Drain and dry it if water is present Turn the fuel valve off Remove the spark plug Remove the bowl drain 1 Remove the crankcase drain screw at the left front of the engine bottom Turn the engine over several times using the electric start Dry the spark plug and reinstall or replace it with a new plug Reinstall the bowl drain Reinstall the crankcase drain screw Turn the fuel valve on Attempt to start the engine If necessary repeat the drying procedure Take the ATV to your dealer for service as soon as possible whether you succeed in starting it or not NOTE If water has been ingested into the PVT follow the procedure on page 95 for drying out the PVT 91 MAINTENANCE AND LUBRICATION Spark Arrestor 4 WARNING 92 Failure to heed the following warnings while servi
89. ur warranty coverage 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 al tered 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 addi tion this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the ATV due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the ATV The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR
90. will result in loss of oil which will cause serious engine damage Always retighten the bleed screw if it s been loosened for service Start the engine and rotate the oil pump lever 2 to its full open position With the engine at idle hold the lever up for thirty seconds to purge all air from the system 73 MAINTENANCE AND LUBRICATION Adjustments Oil Pump If it becomes necessary to increase oil flow into the fuel system the oil pump can be adjusted 1 Before adjusting the oil pump check the engine idle RPM and carburetor settings in the specifications section beginning on page 103 2 Loosen the throttle cable jam nut and turn the adjuster 1 in or out until there is 1 16 1 8 16 32 cm of throttle lever travel before the throttle slide starts to open 3 Place very slight pressure on the throttle lever 2 until all freeplay is removed from the throttle cable to the point where the carb slide is just starting to rise 4 Loosen the locknut 3 Turn the adjuster in or out until all freeplay is removed from the oil pump cable the point where the oil pump arm is just starting to move off its stop The pump stop keeps the pump arm from rotating any further down than the idle position so no visual alignment of marks is necessary Tighten the locknut 74 MAINTENANCE AND LUBRICATION Adjustments Brakes The front and rear brakes are hydraulic disc brakes activated by moving th
91. y the PATENT NOTICE Mfd by All Terrain Vehicle Division Polaris Industries Inc under one or more of the override switch following patents Other patents pending U S Patents 4697665 5036039 5975624 See your Owner s 6016943 6092877 6149540 Manual 6224134 6270108 6340186 D378080 0389440 0400143 Canadian Certification Decal 30 7079906 7171492 SAFETY Safe Riding Gear Always wear clothing suited to the type of riding ATV riding requires special protective clothing for comfort and to reduce the chance 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 that meets or exceeds your state s safety standards and bears either the Department of Transportation DOT label the American National Standards Institute label ANSI z90 1 or the Snell Memorial Foundation label 2 Eye Protection Do not depend on sunglasses for proper eye protection A pair of goggles or a 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 boots with heels like moto cross boots 5 Clothing Always wear long sleeves and long pants to protect arms and legs Riding

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