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Polaris Sprotsman MV7 User's Manual

1. 1 7272 000 m Have an authorized Polaris dealer perform these services 72 MAINTENANCE AND LUBRICATION Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 69 Items not listed in the chart should be lubricated at the General Lubrication interval Lubrication Guide Key gt More often under severe use Polaris Premium Season Grease or grease conforming to NLGI No 2 such as Conoco Superlube M or Mobilegrease Special e Use Polaris Premium U Joint Lube every 500 miles before long periods of storage or after pressure washing or submerging um p e Engine Oil Polaris Premium 4 Synthetic Add to proper level on dip 0W40 Stick Brake Fluid DOT 3 Only Maintain level between fill lines See page 36 Transmission Oil Polaris Premium AGL Synthetic See page 78 Gearcase Lube Front Gearcase Oil Premium Demand Drive Hub Fluid Rear Gearcase Oil Premium ATV Angle Drive Fluid See page 79 Front Prop Shaft Yoke eGrease Grease fittings 3 pumps Fig 1 maximum Ball Joint Fig 2 p Grease Locate fitting on back side of struts and grease with grease gun 73 MAINTENANCE AND LUBRICATION Premium 4 Synthetic Lubricant Polaris Premium 4 Season synthetic engine oil has been specially formulated for use in Polaris 4 cycle engines It s a fully synthetic high performance multi viscosi
2. 12 SAFETY Operator Safety 4 amp 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 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 Fa
3. 64 Driving Uphill 59 E Electrical Switches 33 Electromagnetic Interference 68 EMISSION CONTROL SYSTEMS 68 Engaging Front Gearcase 43 Engine Cooling System 80 81 Engine Stop Switch 33 Equipment Modifications 17 Exhaust Emission Control System 68 F FEATURES 41 48 Filter Systems 89 Footwell Removal 86 Front Gearcase Oil TI Front Wheel Hub Tightening 87 Fuel Filter 39 Fuel Requirements 39 Fuel Safety 49 Fuel Tanks 39 Fuel Valve 0 000008 39 G Gear 40 Gearcase Specification Chart 80 H Handlebars 109 Hauling 54 55 Headlight Housing Replacement 92 Headlight Lamp Replacement 90 High Beam Adjustment 91 High 98 Hour 46 1 Instrument Cluster 44 48 Jetting Chart 113 K Turn Rs 62 L Light Switches 35 TEI GIS beta 90 93 Locking the Parking Brake 37 Low Beam Adjustment 91 Low Range 98 Lower Headlamp Removal Installation 93 Lubrication Guide 73 127 INDEX M Main Switch 33 MAINTENANCE AND LUB
4. 4 Check the oil level Maintain the oil level at the bottom of the fill plug hole 5 Reinstall the fill plug Torque to specification 6 Check for leaks 79 MAINTENANCE AND LUBRICATION Gearcase Specification Chart Gearcase Lubricant Capacity Fill Plug Drain Plug Torque Torque Main Gearcase Premium AGL 15 2 oz 14 ft Ibs 14 ft Ibs Transmission Synthetic Gearcase 450 ml 19 4 Nm 19 4 Nm Lube Front Gearcase Premium Demand 5 oz 8 10 ft Ibs 11 ft Ibs Drive Hub Fluid 150 ml 11 13 6 Nm 15 Nm Rear Gearcase Premium ATV Angle 10 oz Side plug 14 ft Ibs Drive Fluid 300 ml 16 ft Ibs 19 4 Nm 21 7 Nm Engine Cooling System Radiator Coolant Level To ensure that the coolant maintains its ability to protect the engine we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added Polaris recommends the use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water See page 114 for the part numbers of Polaris products NOTE Always follow the manufacturer s mixing recommendations for the freeze protection required in your area Any time the cooling system has been drained for maintenance or repair replace the coolant If the recovery bottle has run dry the level in the radiato
5. Monthly 200 320 Check terminals clean test Monthly 250 400 Inspect level change yearly Rear gearcase oil 25H Monthly 250 400 Inspect level change yearly if equipped Transmission oil Monthly 250 400 Inspect level change yearly Engine breather 25H Monthly 250 400 Inspect clean if needed filter if equipped Perform these procedures more often for vehicles subjected to severe use E Emission Control System Service California m Have an authorized Polaris dealer perform these services 70 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Interval whichever comes first Calendar Miles Km 500 800 Lubricate all fittings pivots cables etc 500 800 Drain bowl periodically and prior to storage 500 800 Inspect adjust lubricate replace if necessary 500 800 Inspect adjust lubricate replace if necessary 500 800 Inspect ducts for proper sealing air leaks 500 800 Inspect adjust replace as needed 1000 1600 Inspect coolant strength seasonally pressure test system yearly General lubrication Carburetor float bowl Throttle Cable ETC Switch ES Choke cable Carburetor air intake ducts flange Drive belt Cooling system Engine oil change 100 H Oil filter change 100 H Oil tank vent hose 100 H if equipped Valve clearance 100 H 1000 1600 Perform a break in oil change at one month 1000 1600 Replace with oil
6. Tighten the carburetor 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 f water has been ingested into the PVT follow the procedure on page 99 for drying out the PVT 95 MAINTENANCE AND LUBRICATION Recoil Housing To prevent possible engine damage always drain the recoil housing 1 after operating the ATV in very wet 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 drain screw is 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 NOTE Do not open the crankcase drain unless the engine has ingested water On 4 cycle engines some engine oil will be lost if the crankcase drain is opened 96 MAINTENANCE AND LUBRICATION Spark Arrestor 4 amp WARNING Failure to heed the following warnings while servicing 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
7. 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 NOTE Ifthe engine is cold use the choke as outlined on page 52 4 Grasp the recoil 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 41 FEATURES Run Flat Tires This ATV is equipped with run flat tires which permit limited operation with a flat tire However ATV load capacity is reduced when tire air pressure is lost Remove cargo from the racks and do not tow a load with flat tires Vehicle characteristics including braking and handling may also be affected by operating with flat tires If you must operate the ve
8. 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 Place the transmission in PARK and start the engine Purge carbon from the system by 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 PARK 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 97 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 On Polaris ATVs the approximate gear ra
9. Warm engines do not normally require the use of the choke Using the choke can cause the spark plug to become wet fouled 1 Position the vehicle on a level surface with the transmission in PARK 2 Lock the parking brake Turn the fuel valve 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 knob pulled half way out may be necessary 4 Ifthe engine is over choked when warm depress the throttle lever fully while cranking to aid in starting 5 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 Cold Weather Operation If the is used year round check the oil level frequently A rising oil level could indicate the accumulation of contaminants such as water or excess fuel in the bottom of the oil tank Water in the bottom of the tank can lead to engine damage and must be drained Water accumulation increases as outside temperature decreases See your Polaris dealer for engine heater kits which provide quicker warm ups and easier starting in colder weather 53 OPERATION Driving Safely Hauling Cargo 2 3 Your ATV has been designed to carry or tow a certain amount of load Always read and understand the load distribution warning labels on the vehicle and never exceed the weight capacities ou
10. indicate a possible fluid leak or low master cylinder fluid level which must be corrected before riding Contact your dealer for proper diagnosis and repairs 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 35 CONTROLS Master Cylinder The brake fluid in the master cylinder 1 which is located on the left handlebar should be checked before each ride The fluid level can be seen through an 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 NOTE When checking the fluid level the ATV must be on level ground with the handlebars straight If the fluid level is low add DOT 3 brake fluid only See page 114 for the part numbers of Polaris products 4 WARNING After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle 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 36 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
11. 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 64 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 not 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 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 SAFETY Operator Safety 4 amp WARNING 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 instruction
12. Information Center the trip meter display contains a decimal point but the odometer displays without a decimal point Mode 3 Hour Meter This mode logs the total hours the engine has been in operation Mode 4 Tachometer The engine RPM is displayed digitally NOTE Small fluctuations in the RPM from day to day may be normal because of changes in humidity temperature elevation and electrical loads 46 FEATURES Instrument Cluster Rider Information Center Diagnostic Mode The diagnostic mode is for informational purposes only Please return your ATV to your dealer for all major repairs As long as the gauge is in the diagnostic mode the wrench icon will remain lit To leave the diagnostic mode turn the key switch off and on Any movement of the tires will also take the machine out of the diagnostic mode To enter the diagnostics mode 1 Turn the key switch off and wait 10 seconds 2 Setthe park brake and shift the transmission to neutral 3 Hold the mode reverse override button and turn the key switch on 4 Release the switch as soon as the display is activated The initial screen display refers to the software version installed in your ATV This information is displayed briefly Use the mode reverse override button to toggle through the diagnostic screens Screen 1 Battery voltage Screen 2 Tachometer Screen 3 AWD diagnostic This gauge indicates whether or not current is flowing through the AWD coil
13. Nm 3 Apply dielectric grease to the inside of the spark plug cap and install the cap onto the plug 4 Tum the engine over several times Oil will be forced in and around the piston rings and ring lands coating the cylinder with a protective film of fresh oil 105 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate Follow lubrication guidelines in the Maintenance Section of the service or owner s manual to completely grease and lubricate the entire vehicle with Polaris Premium Season Grease Battery Maintenance Remove the battery and add distilled water to the proper level Do not use tap water which may contain minerals that reduce battery life Apply dielectric grease to the terminal bolts and terminals Charge the battery at 1 4 amps or less until the specific gravity of each cell is 1 265 or greater Store the battery in a cool dry place Charge can be maintained easily by using Polaris Battery Tender charger PN 2871076 or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point Check the fluid level monthly Engine Anti Freeze Test engine coolant strength and change if necessary Coolant should be replaced every two years Storage Area Covers Set the tire pressure a
14. R P 7 49 1 5 11 1 3 05 1 3 82 1 3 10 1 25 x 8 12 5 psi 25 x 10 12 5 psi Single Control Hydraulic Disc Single Control Hydraulic Disc Hydraulic lock all wheel MacPherson Strut with 8 2 21 cm of travel Progressive Rate with 8 5 21 6 cm of travel Rear Spring Preload Adjust 1 Single Beam on Headlight Pod 50 w 2 Single Beam on Grill 27 w 8 26 w 26 9 w LCD Below 40 F Below 5 C 157 5 Clutch Helix Spring White Yellow EBS 41 37 PN 7041635 PN 5132751 White Yellow PN 7041635 Drive Clutch Spring Driven Blue Green PN 7041157 Blue Green PN 7041157 113 40 F and above 5 C and above EBS 41 37 PN 5132751 POLARIS PRODUCTS Part No Description Engine Lubricant 2870791 Fogging Oil 12 oz Aerosol 2871281 Premium 4 Synthetic OW 40 4 Cycle Engine Oil qt 2871844 Premium 4 Synthetic OW 40 4 Cycle Engine Oil gal 2873602 2873603 2871653 2872276 2870465 2871654 2872277 2871322 2871423 2671460 2871515 2871557 2871312 2871329 2872073 2872348 2871323 60 40 Coolant gal 2871534 60 40 Coolant qt 114 TROUBLESHOOTING Drive Belt and Cover Problems Driving the ATV onto a Shift transmission to low range during loading of the ATV pickup or tall trailer in to prevent belt burning 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
15. 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 69 The following areas need special attention engine oil transmission oil front and rear gearcases and all grease fittings 4 amp 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 95 Have the vehicle serviced by your dealer at the first opportunity 64 OPERATION Driving Safely Driving Over Obstacles Be alert Look ahead and learn to read the terrain you 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 obstac
16. change 1000 1600 Inspect routing condition 1000 1600 Inspect adjust Fuel system filter 100 H 1000 1600 Check for leaks at tank cap lines fuel valve filter pump carburetor replace lines every two years Radiator 100 H 1000 1600 Inspect clean external if applicable surfaces Cooling hoses 100 H 1 1000 1600 Inspect for leaks if applicable pipe 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 these services 3M 6M 12M 12M 12M 12M 2M 71 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Interval whichever comes first Calendar Miles Km H Spark plug 100 H 1000 1600 Inspect replace as needed Ignition Timing 100 H 1000 1600 Wiring 100 H 12M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc 2M Headlight aim Clutches drive 100 H 1000 1600 Inspect clean replace worn and driven parts SOR 8000 4800 vided by the winch manufac Toe adjustment Inspect periodically adjust p Perform these procedures more often for vehicles subjected to severe use Front wheel 100 H 1 1000 1600 Inspect replace as needed bearings Winch System See The Basic Guide to turer when parts are replaced E Emission Control System Service California 6 Winching Techniques
17. 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 diaph Fem operation Use Polaris DOT 3 brake fluid Do not overfill 84 MAINTENANCE AND LUBRICATION Brakes 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 Pads should be changed when 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 The hydraulic auxiliary brake system requires no adjustment NOTE Since this is a rear brake only it will not be as effective as the all wheel single lever system 85 MAINTENANCE AND LUBRICATION Side Panel Removal 1 2 Remove the seat Grasp the rear of the side panel near the rear cab With a firm motion pull the panel outward to disengage the side panel from the grommet Pull the panel downward and rearward to remove it from the ATV Reinstall the side panel by reversing the removal procedure Footwel
18. of a hill when possible Follow proper procedures as outlined in the owner s manual Sidehilling can be the most dangerous type of driving encountered 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 60 OPERATION Driving Safely Driving Downhill 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 Familiarize yourself with operation of the auxiliary brake in the event loss of normal service brakes occurs 4 WARNING Excessive speed can cause loss of control and lead to serious injury or death Always operate slowly when traveling downhill 61 OPERATION Driving Safely Turning Around on a Hill 4 WARNING 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
19. only on models with switchable AWD Screen 4 Gear circuit diagnostic This screen displays the resistance value in ohms being read at the gear switch input of the gauge 47 FEATURES Instrument Cluster Rider Information Center Diagnostic Mode Screen 5 Programmable service interval The purpose of the programmable service interval is to provide the consumer and dealer with a convenient reminder for routine maintenance When your vehicle leaves the factory this feature is set at 50 hours You must enable the programmable service interval before it can be used Once the service interval mode is set with the hours when service is due the hours of actual engine operation are subtracted from the set hours until 0 is reached When the counter reaches 0 the wrench icon will flash quickly for 5 seconds each time the vehicle is started as a reminder that the periodic maintenance is due To set the hours press and hold the mode override button until the wrench icon flashes When it begins to flash release the button The setting will increase by one hour each time the button is pressed Pressing and holding the button will allow the numbers to escalate much faster When the desired time increment is displayed release the button and wait for the wrench to stop flashing When the wrench stops blinking your service hours are set NOTE If you scroll past the intended number hold the button down until the count turns over to 0 You c
20. park brake and perform the K turn as described on page 62 Driving at low RPM or Drive at a higher speed or use low range more frequently low ground speed at The use of low range is highly recommended for cooler approximately 3 7 MPH PVT operating temperatures and longer component life 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 Use low range only RPM low ground speed Utility use plowing snow Use low range only dirt etc Stuck in mud or snow Shift the transmission to low range and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large ob Shift the transmission to low range and carefully use fast jects from a stopped posi brief aggressive throttle application to engage clutch tion WARNING Excessive throttle may cause loss of control and vehicle overturn Belt slippage from water Shift the transmission to neutral Using the throttle vary or snow ingestion into the the engine RPM from idle to full throttle Repeat several PVT system tim
21. 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 68 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 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 Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indi
22. 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 securely 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 2 Remove the drain plug and allow the water to drain Replace the drain plug 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 Allow the engine RPM to settle to idle speed then shift the tra
23. 36039 5975624 6016943 6092877 6149540 6224134 6270106 0378080 0389440 0400143 Canadian Certification Decal 7171492 TRAILER MAX WEIGHT 1500 LBS 682 KG ON LEVEL GROUND 850 LBS 386 KG UP TO 15 GRADE HITCH MAX VERTICAL WEIGHT 150 LBS 68KG 7170509 11 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 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 72 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 pants with kneepads and a jersey with shoulder pads provide the best protection
24. CATION Wheel Installation 1 Place the transmission in PARK and lock the parking brake 4 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 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 4 Lower the vehicle to the ground 5 Torque the wheel nuts to specification Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loosened for maintenance service Specification Front Wheel Nuts 27 ft Ibs 37 Nm Rear Wheel Nuts 27 ft Ibs 37 Nm 88 MAINTENANCE AND LUBRICATION Filter Systems Air Filter Service 1 5 6 Remove the seat release the 1 air box cover clips and 2 remove the air box cover Loosen the clamp and remove the filter Remove the fabric type pre filter 1 from the main filter 2 Wash the pre filter in soapy water then rinse and let dry Reinstall the pre filter over the main filter Replace the main filter if needed Reinstall the filter into the air box and tighten the clamp Do not over tighten the clamp as filter damage could occur Reinstall the air b
25. EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCATION 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 ques tions This policy does not apply to vehicles registered to government offi cials or military personnel 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 Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorize
26. OUBLESHOOTING 115 WARRANTY 222 2ese xw Rr E ERRARE oe 119 MAINTENANCE RECORD 124 INDEX siae aaa uas tertio tula Cera a qe S ik acu 127 VEHICLE IDENTIFICATION NUMBERS Record your vehicle s identification numbers and key number in the spaces provided Remove the spare key and store it in a safe place 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 2 Key Number 3 SAFETY Safety Decals and Locations Warning decals have been placed on the vehicle for your protection Read and follow the instructions of the decals carefully If any of the decals depicted in this manual differ from the decals on your vehicle always read and follow the instructions of the decals on the vehicle 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 A WARNING Improper ATV use can result in SEVERE INJURY or DEATH DOG 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 o
27. OW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions 23 SAFETY Operator Safety 4 amp WARNING 24 POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough slippery or loose terrain WHAT CAN HAPPEN Operating on excessively rough slippery 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 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 SAFETY Operator Safety 4 WARNING 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 4
28. PURPOSE ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service you must take it to a Polaris dealer authorized to repair Polaris ATVs When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Engine Oil 1 Mixing oil brands or using non recommended oil may cause engine damage We recommend the use of Polaris engine oil for your ATV 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty 121 WARRANTY Exported Vehicles
29. RICATION 69 108 MAINTENANCE RECORD 124 126 Making Turns 57 Master Cylinder 36 Mode Reverse Override Switch 33 N Noise Emission Control System 68 Odometer 46 Oil Change eso n 76 Oil Check ner Ree 75 Oil Filter Change 76 OPERATION 49 67 Operator 13 32 Parking Brake 37 Parking on an Incline 67 Periodic Maintenance Chart 69 72 POLARIS PRODUCTS 114 Pre Ride Inspection 51 Premium 4 Synthetic Lubricant 74 PVT Drying 99 PVT System 98 99 R Radiator Coolant Level 80 81 Rear Gearcase Oil 79 Rear 5 109 Recoil Housing 96 Recoil Starter 41 Reverse Override Switch 33 Rider Information Center 45 48 Run Flat 42 S Safe Riding 12 SABETY i 205m6esays E 8 32 Safety Decals and Locations 8 11 Safety Training 13 Severe Use iocsc lel RU ER ows 69 128 S Side Panel Removal 86 Sidehilling 60 Spark 68 97 Spark Plug Removal and Replacement 94 Spark 94 SPECIFICATIONS 112 113 Starting a Cold Engine 52 Starting
30. STMENTS 109 111 Age Restrictions 13 Air Filter 89 All Wheel Drive 43 Automatic Transmission 40 Auxiliary Brake 85 Heke 43 B Battery e le ER 100 102 Battery Fluid 102 Battery Installation 101 Battery Maintenance 106 Battery Removal 101 Battery Storage 102 Belt bifes ert 40 Brake Fluid 36 38 Brake Lever 35 Brake Auxiliary 38 Brakelight 2 210 93 Brakes ce bl eye 84 85 Break In 50 Breather 89 C Camber and Caster 109 Carburetor Idle RPM 110 Choke sinc eins week ER Yers 39 Chrome Wheel Care 107 108 Cleaning mre 103 106 Clutching 113 Cold Weather Operation 58 CONTROLS 33 40 Coolant 1 82 Cooling System 82 Cooling System Operation 82 COrOSION ts 107 Crankcase Emission Control System 68 D Diagnostic Mode 47 48 Driving Downhill 61 Driving in Reverse 66 Driving on Slippery Surfaces 58 Driving Over Obstacles 65 Driving Procedures 56 Driving 54 67 Driving Through Water
31. Spain 7 Owner s Cm for Safet 5e ar 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 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 Operate on public roads A collision can occur with another vehicle Operate at speeds too fast for your skills or the conditions Use ALCOHOL or DRUGS before or while operating this vehicle Carry Passengers ALWAYS Avoid paved surfaces which may adversely affect handling and control 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 9919959 Rev 01 PRINTED IN THE USA The Way Out AWARNING 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 removed please call 1 800 342 3764 for assistance PLRIGRIS For 50 years we ve been
32. 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 E SS procedures for climbing hills as described in the owner s manual Always check the terrain i Ba carefully before ascending any hill Never operate the ATV on hills steeper 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 25 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 is required when braking while INS queris traveling downhill See page 61 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 26 SAFETY Operator Safety 4
33. WARNING POTENTIAL HAZARD EON Improperly crossing hills and Wa e TE turning on hills Do 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 62 Use 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 27 SAFETY Operator Safety 4 amp WARNING 28 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 If all forward speed is lost Keep your weight uphill Apply the brakes Lock the parking brake when fully stopped If the ATV begins rolling backwards Keep weight uphill Never apply engine power Never apply the rear brake while rolling backwards Apply the single lever brake gradually When fully stopped apply the rear brake as well and then lock the parking brake Dismount on uphill side or to either side if ATV is pointed straight uphill Turn the ATV around and remount f
34. Your ATV is equipped with a 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 distance than the inside wheel when turning and the inside tire must slip traction slightly To turn steer in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest This technique alters the balance of traction between the rear wheels allowing the turn to be made smoothly The same leaning technique should be used for turning in reverse 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 57 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 2 58 Slow down when entering slippery areas Engage AWD before wheels begin to lose traction Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward CAUTION Severe damage to drive train may occur if the AWD is engaged whil
35. a Warm Engine 53 Starting the Engine 52 53 Steering Assembly 83 Stop 33 Storage 103 106 Storage Tips 104 106 Switches sie eae eL ee 33 T TABLE OF CONTENTS 5 Tachometer 46 93 Throttle Cable Freeplay 111 Throttle 34 TAS ure quem RR pO 87 Tires 42 Toe Alignment 83 Transmission 78 Transporting the 108 Trip Meter 46 TROUBLESHOOTING 115 118 Turning Around on aHill 62 63 V VEHICLE IDENTIFICATION NUMBERS 1 Vehicle Immersion 95 WARRANTY 119 123 WELCOME S ik 3 Wheel Installation 88 Wheel Nut Torque Specifications 88 Wheel Removal 87 Winch Operation Switch 33 Winch Switch Front Rear 33 Winches si eek er e ya 42
36. an then reset the number If the service interval is enabled on your ATV and you wish to turn it off toggle to the service interval mode Press and hold the mode button for approximately 7 seconds until the word OFF appears in the Rider Information Center Screen 6 Miles Kilometers toggle The display in the tripmeter and odometer can be changed to display either kilometers or miles The current display mode will be shown as KM or MP To change hold in the mode button until the letters flash then press and release the button once When the display stops flashing the mode has been set 48 OPERATION Fuel Safety 4 amp WARNING Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always refuel with the engine stopped and outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing 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 Turn the fuel valve off whenever the ATV is stored or parked 4 WARNING The engine exhaust from this product contains chemicals known
37. andling characteristics of the vehicle Use only Polaris approved accessories and familiarize yourself with their function and effect on the vehicle 17 SAFETY Operator Safety 4 amp WARNING 18 POTENTIAL HAZARD Operating this ATV without proper instruction WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Polaris 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 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 SAFETY Operator Safety 4 amp WARNING POTENTIAL HAZARD Carrying a passenger on an ATV WHAT CAN HAPPEN Car
38. at tire remove all cargo from the vehicle before riding further Do not exceed 50 miles 80 km at 25 MPH 40 km h Have the tire inspected by a dealer before further use Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your risk of losing control Loads should be centered carried as low as possible and firmly secured to the racks With dual racks load distribution 1 3 front 2 8 rear is best For stability on rough or hilly terrain reduce speed and cargo Do not block headlight Be careful if load extends over the side of the rack Read Owner s Manual for more detailed loading information 7173016 NEVER ride as a passenger Passengers can cause a loss of control resuiting in SEVERE INJURY or DEATH 7172566 ATTENTION Operation of this vehicle without the air Specific carburetor jetting and filter element will severely damage the adjustments are required depending engine on temperature and altitude See your Owner s Manual Clean pre filter element often more frequent cleaning required in dusty Factory setting conditions Do not operate vehicle 40 to 80 F at 0 3000 feet without pre filter 5 to 27 C at 0 900 meters 7172922 SAFETY Safety Decals and Locations AWARNING A WARNING e Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle wi
39. ating on unfa miliar terrain Be alert to changing terrain conditions Never operate on excessively rough slippery or loose terrain 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 15 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 before attempting larger hills Always follow proper procedures for climbing hills Check the ter rain carefully before ascending a hill Never climb hills with exces sively 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 mas
40. behind the ATV before operat ing in reverse When it s safe to proceed in reverse move slowly and avoid turning at sharp angles Always use the size and type of tires specified for your ATV and always maintain proper tire pressure Never modify an ATV through improper installation or use of acces sories 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 distance for braking 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 h
41. brake is disengaged before operating Locking the Parking Brake 1 2 Place the transmission in PARK Squeeze and release the brake lever 1 two or three times then squeeze and hold Push the park brake lock 2 forward to engage the brake Release the brake lever To release the parking brake lock squeeze and release the brake lever It will return to its unlocked position N A gii Important Safeguards The parking brake may relax if left on for a long period of time AI 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 CONTROLS Auxiliary Brake 4 WARNING Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover which could result in serious injury or death Use caution when applying the auxiliary brake Do not aggressively apply the auxiliary brake when going forward The rear wheels may skid and slide sideways causing loss of control and serious injury or death Your Polaris ATV has an auxiliary brake 1 for added safety It s 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 s
42. cate 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 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 4 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 69 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first Maintenance Interval whichever comes first Calendar Miles Km Pre Ride ire i Make adjustments as need reser Servos eii ii oT in spen Aneel Re a i En m spes T uM Air filter pre filter pasas Inspect clean often Drain deposits when visible Coolant Daily Check level daily change EX coolant every 2 years Headlamp tail E Check operation Air filter Weekly main element Recoil housing Weekly Drain water as needed check often if operating in wet conditions Inspect replace as needed Monthly 100 160 Inspect periodically
43. ce 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 34 CONTROLS Light Switches The light switch is located on the left handlebar It s used to turn the lights on and off and to switch the lights from HI to LO NOTE The lights won t work unless the key is in the ON position and the shut off switch is in the RUN position 4 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 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 Brake Lever The front and rear brakes are applied 1 by squeezing the brake lever 1 toward the handlebar The Am and S 9 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
44. d used for racing or used for purposes other than for which it was manufactured or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the ATV due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the ATV The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law 120 WARRANTY ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
45. d 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 be fore you move Vehicles importation rules vary considerably from country to country You may be required to present documentation of your move to Polaris Industries in order to continue your warranty cov erage You may also be required to obtain documentation from Polaris Industries in order to register your vehicle in your new country 122 WARRANTY Exported Vehicles 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 pur chased and you have not followed the procedure set out above your vehicle will no longer be eligible for warranty or service bulletin cover age of any kind Vehicles registered to Government officials or mili tary 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 123 MAINTENANCE RECORD 124 MAINTENANCE RECORD 125 MAINTENANCE RECORD 126 A Accessories 69 103 ADJU
46. drain pan Dispose of properly Clean and reinstall the drain plug Torque to specification Remove the fill plug and add the recommended fluid Reinstall the fill plug Torque to specification Check for leaks Reinstall the footwell cU 78 MAINTENANCE AND LUBRICATION Rear Gearcase Oil The rear gearcase has two fill plugs The rear fill plug is located on the rear of the gearcase and is not easily accessible The side fill plug 1 is located on the left side of the gearcase Use the side fill plug when checking or changing oil Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 69 Maintain the oil level 2 even with the bottom of the side fill hole Refer to the Gearcase Specifications Chart on page 80 for recommended lubricants capacities and torque specifications See page 114 for the part numbers of Polaris products Oil Check 1 Position the vehicle on a level surface 2 Remove the side fill plug and view the oil level through the fill plug hole 3 Add the recommended gearcase oil as needed 4 Reinstall the fill plug Torque to specification Oil Change 1 Place a drain pan beneath the drain and remove the drain plug Catch and discard used oil properly 2 Clean and reinstall the drain plug with a new sealing washer Torque to specification 3 Remove the side fill plug and add the recommended fluid
47. e Always block the rear wheels on the downhill side as shown in the illustration Shut off the fuel supply 67 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 Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system The system does not allow the blow by gases to enter the atmosphere Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design including factory set fuel delivery and ignition The engine and related components must be maintained at Polaris specifications to achieve optimal performance Adjustment to engine idle is the only adjustment Polaris recommends that the operator perform Any other adjustments should be performed by an authorized Polaris dealer The emissions label is located on the recoil cover 4 WARNING The installation of devices that effectively increase exhaust emissions beyond their legal limits will void all manufacturer warranties and may violate laws governing the registration and operation of this vehicle Spark Arrestor Your Polaris vehicle has a spark arrestor that was tested and approved in accordance with the USDA Forest Service Standard 5100 1C Fed eral law requires that this
48. e the wheels are spinning Always allow the rear wheels to stop spinning before engaging AWD or engage AWD before wheels begin to lose traction 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 OPERATION Driving Safely Driving Uphill 25 Maximum Whenever traveling uphill follow these precautions Always travel straight uphill Avoid steep hills 25 maximum Keep both feet on the footrests Transfer your weight forward Proceed at a steady rate of speed and throttle opening Oy Uy Re Uo ES Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle 4 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 59 OPERATION Driving Safely Sidehilling 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
49. ed loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing downhill USE EXTREME CAUTION when operating with loads that extend over the rack sides Stability and maneuverability may be adversely affected causing the vehicle to overturn DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the front rack DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS 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 a hill 55 OPERATION Driving Safely Driving Procedures 56 Sit upright with both feet on the footrests and both hands on the handlebars Start the engine and allow it to warm up then shift the transmission into gear Check your surroundings and determine your path of travel Release the parking brake Slowly depress the throttle with your right thumb and begin driving Vehicle speed is controlled by the amount of throttle opening Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces OPERATION Driving Safely Making Turns
50. el Care if equipped Transporting the ATV Follow these procedures when transporting the vehicle 1 Turn off the engine and remove the key to prevent loss during transporting 2 Place the transmission in PARK and lock the parking brake 3 Turn the fuel valve off and be sure the fuel caps oil cap and seat are installed securely 4 Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets 108 ADJUSTMENTS 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 springs are available through your Polaris dealer Handlebars The handlebars can be adjusted for rider preference 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 1 Remove the upper headlight pod 2 Loosen the four bolts 1 3 Adjust the handlebar to the desired height Be sure the handlebars do not con
51. embly into the headlight assembly Turn the headlight harness counterclockwise to secure Taillight Brakelight Lamp Replacement 1 Remove the taillight lens cover mounting screws 1 2 Remove the lens cover 2 and gasket 3 Remove the lamp 3 4 Apply dielectric grease to the socket and install the new lamp 5 Test the taillight brakelight 6 Reinstall the gasket and lens cover 93 MAINTENANCE AND LUBRICATION Spark Plugs Always use the spark plugs recommended for your ATV Refer to the specifications section beginning on page 112 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 Thetip should not be white A white insulator tip indicates overheating caused by use of an improper spark pl
52. er for testing and recharging Power plug leads may need to be bent down so that the battery cover can be installed Replenishing Battery Fluid A poorly maintained battery will deteriorate rapidly Check the battery fluid level often The fluid level should be kept between the upper and lower level marks 1 To refill use only distilled water Tap water contains minerals that are harmful to a battery 4 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 102 MAINTENANCE AND LUBRICATION Accessories Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights Accessory outlets are available for all models Polaris also has a wide range of additional accessories available for your ATV See your Polaris dealer Cleaning and Storage See page 114 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 t
53. es as required During this procedure the throttle should not be held at the full position for more than 10 seconds Clutch seals should be inspected for damage if repeated leaking occurs 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 115 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 Tripped circuit breaker Reset the breaker Low battery voltage Recharge battery to 12 5 VDC 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 your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs 116 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 Mechanical failure Engine Runs Irregularly Stalls or Misfires Possible Weak Spark Cause Solution Other mechanical failure Possible Lean Fue
54. g in severe injury or death Never run an engine in an enclosed area Place the transmission in PARK and lock the parking brake Turn the fuel valve on Sit on the vehicle and pull the choke knob 1 out until it stops F N SS when the knob is pulled 17 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 Turn the engine stop switch to RUN NOTE Do not press the throttle while starting the engine 2 52 Turn the ignition key past the ON position to engage the starter Activate the starter for a maximum of five seconds releasing the key when the vehicle starts If the engine does not start release the starter and wait five seconds Activate the starter for another five seconds if necessary Repeat this procedure until the engine starts If the engine slows or stops position the choke knob half way in to allow proper engine warm up Vary the engine RPM slightly with the throttle to aid in warm up When the engine idles smoothly push the choke completely in CAUTION Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle OPERATION Starting the Engine Starting a Warm Engine
55. h the oil filter Using an oil filter wrench turn the filter counterclockwise to remove Using a clean dry cloth clean the filter sealing surface on the crankcase Lubricate the o ring on the new filter with a film of fresh engine oil Check to make sure the o ring is in good condition Install the new filter and turn by hand until the filter gasket contacts the sealing surface then turn and additional 1 2 turn Remove the dipstick and fill the sump with two quarts 1 9 1 of recommended oil Place the gear selector in PARK and set the parking brake Start the engine and let it idle for one to two minutes Stop the engine and inspect for leaks Re check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick Dispose of used filter and oil properly MAINTENANCE AND LUBRICATION Front Gearcase Oil Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 66 Maintain the oil level even with the bottom of the fill hole threads 1 Refer to the Gearcase Specifications Chart on page 80 for recommended lubricants capacities and torque specifications Use of other oils may result in improper operation of components See page 114 for the part numbers of Polaris products Cil Check 1 Position the vehicle on a level surface 2 Remove the fill plug 2 and view the oil level 3 Add the recommended gearca
56. he 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 and warning labels 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 Polaris does not recommend waxing the finish on this vehicle 103 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips 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 Clean the 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 Stabilize the Fuel 1 Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer to both tanks Follow the instructions on the container for the reco
57. helmet A increases the risk of a 4 severe head injury or z Po J 7 death in the event of an i VILIS TE OO nY 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 and long pants SAFETY Operator Safety WARNING 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 4 amp 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 21 SAFETY Operator Safety 4 amp WARNING 22 POTENTIAL HAZARD Attempting wheelies jumps and ot
58. helping Polaris customers find The Way Out It s been a fun ride But then after all these years That s what we re all about Visit our Web site at www polarisindustries com POLARIS The Way Out P a n ag A od a 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 Sportsman MV7 Owner s Manual P N 9919959 2 WELCOME Thank you for purchasing a Polaris vehicle and welcome to our world wide family of Polaris owners We proudly produce an exciting line of utility and recreational products Polaris Recreational and Utility Vehicles Snowmobiles All terrain vehicles ATVs e Watercraft RANGER utility vehicles Victory motorcycles 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 de
59. her 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 xs exhibition driving 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 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 SAFETY Operator Safety 4 WARNING 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 4 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 overturn Mere e H
60. hicle with a flat tire drive no further and no faster than necessary and travel on smooth and level terrain whenever possible 4 amp WARNING Failure to reduce travel distance vehicle speed and cargo weight when air pressure is lost in run flat tires could result in loss of control or tire damage This could lead to serious injury or death If you must operate the vehicle with flat tires remove all cargo and towed loads from the ATV and do not exceed 50 miles 80 km at 25 MPH 40 km h Have the tire s inspected by an authorized Polaris dealer as Soon as possible and before further use Winches Your vehicle is equipped with both a front 1 and a rear 2 winch These winches operate independently Use the pod switch to select one of the winches Use the handlebar switch to operate the selected winch Refer to the winch manufacturer s Basic Guide to Winching Techniques provided with your ATV for complete winch operation instructions 42 FEATURES All Wheel Drive AWD System Polaris 4 wheel drive ATVs are equipped with a unique Polaris exclusive All Wheel Drive AWD system which is activated by a switch 1 on the right handlebar When the switch is off the ATV is in 2 wheel drive at all times When the switch is on the ATV is in AWD and the AWD indicator light in the instrument cluster will be on When in AWD the front gearcase will automatically engage any time the rear wheels
61. ide surface of the rear tires on each side of the vehicle and goes around the stands in front of the vehicle 2 4 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 1 5 3 mm more than the front measurement NOTE f you discover improper alignment see your Polaris dealer for service 83 MAINTENANCE AND LUBRICATION Brakes The front and rear brakes are hydraulic disc brakes activated by moving the 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 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 1 Always keep brake fluid at an adequate level see page 36 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 level Do not overfill NOTE Under normal operation the
62. ily pre ride inspection checklist See page 51 Pull only light loads During the break in period change both the oil and the filter at 20 hours 200 miles or one month whichever comes first OPERATION Pre Ride Inspection 4 amp WARNING If 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 Brake system lever travel Page Ensure proper operation Ensure proper level Ensure proper operation Inspect lubricate if necessary Inspect lubricate if necessary Ensure free operation HER nspect condition and pressure nspect ensure fastener tightness nspect ensure tightness Ensure proper levels CNN EM Ensure proper operation Ensure operation Ensure proper operation denn Drain deposits whenever visible o o Headlamp Check operation apply Polaris dielec tric grease when lamp is replaced Brake light tail lamp Check operation apply Polaris dielec 93 tric grease when lamp is replaced Riding gear Wear helmet goggles protective 2 clothing Coolant level if applicable Ensure proper level Coolant hoses if applicable Inspect for leaks 51 OPERATION Starting the Engine Starting a Cold Engine 4 WARNING NOTE The variable choke is fully on 4 Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resultin
63. is warranty begins on the date of purchase This warranty is transferrable to another consumer during the warranty period through a Polaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty THE PURCHASER MUST COMPLETE AN ATV SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE ATV No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your ATV is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage 119 WARRANTY WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any ATV that has been altered structurally modified neglected improperly maintaine
64. ive battery cable first 4 Disconnect the red positive battery cable next 5 Lift the battery out of the ATV Be careful not to tip the battery sideways which could spill electrolyte 4 CAUTION If electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle Battery Installation 1 2 Set the battery in the battery holder Install the battery vent tube NOTE The vent tube must be free of obstructions and securely OX M ope a installed If not battery gases could accumulate and cause an explosion The tube should be routed away from the frame and body to prevent corrosion Avoid skin contact with electrolyte which can cause severe burns First connect and tighten the red positive cable Second connect and tighten the black negative cable Reinstall the battery cover and attach the hold down strap Verify that cables are properly routed NOTE 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 charged can damage the battery and result in a shorter life It can also hinder vehicle performance 101 MAINTENANCE AND LUBRICATION Battery Battery Storage When the vehicle is placed in storage for three months or more the battery should be removed stored out of the sun in a cool dry place and tested monthly Before reusing take the battery to your deal
65. l Mixture Cause Solution Possible Rich Fuel Mixture Cause Solution 117 Kinked or plugged fuel vent line Inspect and replace TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Kinked or plugged fuel vent line Water present in fuel Overuse of choke Fouled or defective spark plugs Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Clogged air filter Reverse speed limiter malfunction Electronic Throttle Control malfunction Other mechanical failure Overheated engine Clean radiator screen and core Clean engine exterior See your Polaris dealer Engine Overheating Possible Cause Solution Debris lodged in screen Remove and clean the screen Pull on the top portion of the screen then remove the lower portion Plugged Radiator Use a garden hose to flush any debris from the radiator fins NOTE High pres sure washers can deform the radiator fins and reduce cooling efficiency 118 WARRANTY LIMITED WARRANTY Polaris Sales Inc 2100 Highway 55 Medina MN 55340 gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris 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 Th
66. l Removal 1 2 4 86 Remove the four screws 1 on the bottom of the footwell Use a flat screwdriver or sidecutters to remove the plastic rivets 2 securing the footwell to the fenders Use a phillips screwdriver and wrench to remove the mudflap screws 3 Remove the footwell MAINTENANCE AND LUBRICATION 4 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 the 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 mm or less Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less See illustration 1 8 8 mm Front Wheel Hub Tightening Front wheel bearing tightness and spindle A nut retention are critical component operations All service must be performed by your authorized Polaris dealer Wheel Removal 1 Stop the engine place the transmission in PARK 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 87 MAINTENANCE AND LUBRI
67. les are immediately visible Travel with caution in unfamiliar terrain 65 OPERATION 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 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 Your Polaris ATV is equipped with a reverse speed limiter The override button should be used with caution as rearward vehicle speed is greatly increased Do not operate at wide open throttle 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 66 OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 2 3 4 Turn the engine off Place the transmission in PARK Set the parking brak
68. lose traction When the rear wheels regain traction the front gearcase will automatically disengage NOTE The override switch allows activation of AWD in reverse if the AWD switch is on See page 33 There is no limit to the length of time the vehicle may remain in AWD Engaging Front Gearcase The AWD switch may be turned on or off while the vehicle is moving Initially the vehicle s electronic system will not enable the AWD until the engine RPM is below 3100 Once enabled the AWD remains enabled until the AWD switch is turned off If the switch is turned off while the front gearcase is moving it will not disengage until the rear wheels regain traction Engage the AWD switch before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to AWD CAUTION Switching to AWD while the rear wheels are spinning may cause severe drive shaft and gearcase damage Always switch to AWD while the rear wheels have traction or are at rest 43 FEATURES Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel The instrument cluster measures distance in miles or kilometers as well as hours of operation It also includes a reverse speed limiter function that limits the ATV s speed to approximately 7 9 mph Refer to page 33 for additional information PESLARIS 1 Rider Information Center Speed
69. ly upward or downward 1 Loosen the headlamp mounting bolt 1 2 Tilt the headlamp upward or downward 3 Tighten the bolt 91 MAINTENANCE AND LUBRICATION Lights Headlight Housing Replacement 1 2 3 M 00 53 o NOTE The distance from the 10 92 Remove the two screws on the lower front corners of the headlight pod Lift the pod slightly while depressing the tabs at the rear of the pod Lift the pod cover and disconnect the speedometer harnesses from the speedometer Unplug the headlamp from the wiring harness Use a small screwdriver to remove the o rings from the headlight mounting tabs Pull the headlight housing up to release it from the locking tabs Lift the adjusting knob up to remove it from the locking tabs Carefully pull the assembly up and out of the pod Reverse the steps to install the new housing and reassemble the pod headlamp parting line to the end of the adjustment knob stop is 5 1 8 18 cm Adjust the headlight aim by turning the adjusting knob MAINTENANCE AND LUBRICATION Lights Lower Headlamp Removal Installation 1 Turn the back of the headlight harness 1 in a clockwise direction A 2 Pull the harness assembly out from the headlight assembly 4 3 Remove the headlamp and install 1 ce the new headlamp 4 Install the new headlamp and harness ass
70. manual If the vehicle stalls while climbing a hill never back down the hill Use the K turn to turn around 62 OPERATION Driving Safely Turning Around on a Hill 1 2 3 Stop the vehicle and lock the parking brake while keeping body weight uphill Leave the transmission in forward and shut off the engine Dismount on the uphill side of the vehicle or on the left if the vehicle is pointing straight uphill Staying uphill of the vehicle turn the handlebars full left While holding the service brake 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 Lock the parking brake and remount the vehicle from the uphill side keeping body weight uphill Restart the engine with the transmission still in forward Release the parking brake and proceed slowly controlling speed with the service brake until the vehicle is on more level ground 63 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 through water 1 Determine water depths and current before crossing 2 Choosea 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
71. miliarize yourself with all laws and regulations concerning the operation of the ATV 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 13 SAFETY Operator Safety The following two pages identify signal words and symbols that appear in this manual Your safety is involved when these words and symbols are used Become familiar with their meanings before reading the manual A A 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 14 A note will alert you to important information or instructions SAFETY Operator Safety 4 amp 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 Read this manual and all labels carefully and follow the operating procedures described Never operate an ATV without pr
72. mmended amount NOTE Carbon Clean wil also reduce the possibility of bacterial growth in the fuel system 2 Fill the fuel tanks 3 Operate the engine for 15 20 minutes to disperse the stabilizer through the fuel in the tank and carburetor 4 Switch tanks and operate for an additional 5 10 minutes 5 Turn the fuel valve off 6 Drain the carburetor bowl Air Filter Air Box Inspect and clean or replace the pre cleaner and air filter Clean the air box and drain the sediment tube Breather Filter Inspect and clean or replace the breather filter 104 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips Recoil Housing Remove the recoil housing drain plug and drain any moisture Oil and Filter Warm the engine and change the oil and filter Fluid Levels Inspect the following fluid levels and change if necessary front and rear gearcases transmission and brake fluid change every two years or as required if fluid looks dark or contaminated Fog the Engine 1 Remove the spark plug and add 2 3 tablespoons of Premium 4 Synthetic 0W40 engine oil To access the plug hole use a section of clear 1 4 hose and a small plastic squeeze bottle filled with the pre measured amount of oil NOTE this carefully If you miss the plug hole oil will drain from the spark plug cavity into the hole at the front of the cylinder head and appear to be an oil leak 2 Reinstall the spark plug Torque to 18 ft Ibs 24
73. n public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS IF OWNER S MANUAL IS MISSING CONTACT A POLARIS DEALER FOR A REPLACEMENT 2 1997 2000 7172560 4 WARNING Never operate this ATV on HILLS steeper than 25 degrees 285 To prevent flipover hilly terrain when going up down use throttle and brakes gradually REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent flipover avoid sudden braking or sharp turns Use OVERRIDE for reverse speed limiter with caution To prevent loss of control never activate override button with open throttle When this ATV is not in operation or unattended place shift in the park position 7172561 SAFETY Safety Decals and Locations A WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE IN PSI KPa FRONT 5 34 5 REAR 5 34 5 MAXIMUM WEIGHT CAPACITY Gross Vehicle Weight INCLUDING MACHINE DRIVER AND CARGO IS 1700 LBS 771 kg This vehicle is equipped with run flat tires In the event of a fl
74. nd 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 106 MAINTENANCE AND LUBRICATION 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 Polish the clean chrome wheels periodically Use an automotive grade chrome polish 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 Chrome wheels exposed to road salt or salt in the air in coastal areas are more susceptible to corrosion if not properly cleaned Clean chrome wheels more often if they re exposed to salt or other corrosive elements 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 107 MAINTENANCE AND LUBRICATION Chrome Whe
75. nsmission to the lowest available range Test for belt slippage If the belt slips repeat the process Take the vehicle to your dealer for service as soon as possible 99 MAINTENANCE AND LUBRICATION Battery Always keep battery terminals and connections free of corrosion If cleaning is necessary remove corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the terminals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into a conventional battery A 100 WARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN MAINTENANCE AND LUBRICATION Battery Battery Removal 1 Disconnect the hold down strap holding the battery in position and remove battery cover 2 Remove the battery vent tube 3 Disconnect the black negat
76. ollowing the procedure described in the owner s manual See page 62 SAFETY Operator Safety 4 amp WARNING 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 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 4 amp WARNING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Skidding or sliding can cause loss of control If 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 4 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 29 SAFETY Operator Safety 4 amp WARNING 30 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
77. ometer needle in addition to showing vehicle speed the needle flashes when a warning condition exists 3 Speedometer CAUTION To prevent damage wash the vehicle by hand or with a garden hose using mild soap Do not use alcohol to clean the instrument cluster Immediately clean off any gasoline that splashes on the instrument cluster Do not allow insect sprays to come into contact with the lens 44 FEATURES Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster segments will light up for 2 5 seconds at start up NOTE Ifthe instrument cluster fails to illuminate a battery over voltage may have occurred and the instrument cluster may have shut off to protect the cluster s electrical system If this occurs take the ATV to your Polaris dealer for proper diagnosis 1 Gear Indicator As the shift lever is moved this indicates the gear the transmission is in 3 4 5 6 High Range L Low Range 7 N Neutral Reverse 8 P Park 2 2 AWD Indicator This indicator illuminates when the electrical portion of the AWD system is enabled 3 Engine Hour Display Indicator 1 Service Interval Diagnostic Mode Indicator 5 Low Battery and Over Voltage This warning usually indicates that the ATV is being operated at an RPM too low to keep the battery charged A low battery warning may also occur under normal operation if the machine is at idle and high elec
78. oper instruction 7ake 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 Never allow anyone under 16 years of age to operate this ATV 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 Always avoid operating an ATV on paved surfaces including side walks driveways parking lots and streets Never operate an ATV on a public street road or highway including a dirt or gravel road 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 Never consume alcohol or drugs before or while operating an Never operate at excessive speeds Travel at speeds appropriate for the terrain visibility and operating conditions and your experience Never attempt wheelies jumps or other stunts 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 Always keep both hands on the handlebars and both feet on the foot rests of the ATV during operation Always travel slowly and use extra caution when oper
79. ox cover and the seat Breather Filter Hose 1 2 To access the breather filter 3 remove the left side panel as outlined on page 86 The breather filter is on the hose that runs between the engine and air box Remove the clamps and pull the filter out of the hoses NOTE It s not necessary to remove the lower hose from the engine 3 4 3 Inspect the filter for debris Blow gently through the filter in the direction of the arrow to check for clogging Replace if needed Check the hoses for cracks deterioration abrasion or leaks Replace as needed Reinstall the filter and secure the clamps NOTE The filter is effective with the arrow pointing in either direction CAUTION Operation of your vehicle without a breather filter can cause engine damage Always reinstall the breather filter after removing for service 89 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 4 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 Allow lamps to before servicing Headlight Lamp Replacement 1 2 3 4 5 6 7 Remove the two scre
80. perate this vehicle have an increased risk of overturn and loss of control which could result in severe injury or death CAUTION Exhaust system components are very hot during and after use of the vehicle Hot components can cause serious burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system Use caution when traveling through tall grass especially dry grass CONTROLS Electrical Switches 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 Mode Reverse Override Switch 1 This vehicle is equipped with a reverse speed limiter system To gain additional power while backing depress the override switch NOTE The override switch also allows activation of AWD in reverse if the AWD switch is on This switch is also used to toggle through the different modes of the rider information center See page 44 Engine Stop Switch 2 The engine will not start or run when the switch is in the OFF RUN OFF OFF position Its purpose is to provide the operator with a quick means of engine 01 shutdown in case of an emergency Main Switch 3 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 start
81. r should be inspected Add coolant as needed 4 WARNING Escaping steam can cause severe burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 80 MAINTENANCE AND LUBRICATION Engine Cooling System Radiator Coolant Level 1 ON UA cB Remove the bolts securing the front rack See illustration Remove the rack Remove the pressure cap 1 Using a funnel slowly add coolant through the radiator filler neck Reinstall the pressure cap Reinstall the front rack NOTE Use of a non standard pressure cap will not allow the recovery system to function properly Contact your dealer for the correct replacement part MAINTENANCE AND LUBRICATION Engine Cooling System Coolant Level The recovery bottle 1 is located on the left side of the machine To access the recovery bottle remove the left side panel as outlined on page 86 Maintain the coolant level between the minimum and maximum marks on the bottle when the fluid is cool Add coolant as needed Cooling System Operation The engine coolant level is controlled or maintained by the recovery system The recovery system components are the recovery bottle radiator filler neck radiator pressure cap and connecting hose As coolant operating temperature increases the expanding heated excess coolant is forced out of the radiator past the pressure cap and into the reco
82. ry with a clean cloth NOTE Lift the lever lock 2 to remove the dipstick 3 Reinstall the dipstick completely but do not lock it The dipstick must be completely seated 4 Remove the dipstick and check the oil level Maintain the oil level between the SAFE and ADD marks 3 Do not overfill NOTE Due to the dipstick entry angle into the crankcase the oil level will read higher on the bottom side of the dipstick Always read the level on the upper surface 4 of the dipstick 5 After reinstalling the dipstick seat the lever lock SAFE ADD 8 OZ 75 MAINTENANCE AND LUBRICATION Oil and Filter Change Change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 69 Always install a new filter when changing the oil 1 2 3 Position the vehicle on a level surface Run the engine for two to three minutes until warm Stop the engine Clean the area around the drain plug Place a drain pan beneath engine crankcase and remove the drain plug CAUTION Hot oil can cause serious burns Do not allow hot oil to touch skin Allow the oil to drain completely Replace the sealing washer on the drain plug NOTE The sealing surfaces on drain plug and crankcase should be 10 11 12 13 14 15 16 76 clean and free of burrs nicks or scratches Reinstall the drain plug and torque to 20 ft Ibs 27 Nm Place shop towels beneat
83. rying a passenger greatly reduces the operator s ability to balance and control the ATV which could cause an accident 72 and injury to the EM 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 4 WARNING POTENTIAL HAZARD Operating 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 19 SAFETY Operator Safety 4 amp WARNING POTENTIAL HAZARD Operating this ATV on is public streets roads or a highways Sud WHAT CAN HAPPEN The ATV could collide uy 20 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 WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet eye protection and protective clothing WHAT CAN HAPPEN Operating an ATV without A an approved
84. s NOTE Both the main switch and the emergency engine stop switch will shut off all electrical power to the vehicle including lights To stop the engine slide the stop switch either right or left to the OFF position Front Rear Winch Switch 4 Use the switch on the pod to select either the front or rear winch Winch Operation Switch 5 After selecting either the front or rear winch with the switch on the pod use the handlebar switch to operate the winch Winch operation instructions can be found in The Basic Guide to Winching Techniques provided by the winch manufacturer 33 CONTROLS 4 WARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death Never start or operate an ATV with a sticking or improperly operating throttle Always contact your dealer for service 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 1 The throttle lever is spring loaded Engine speed returns to idle when the lever is released This ATV is equipped with Polaris Electronic Throttle Control ETC which is designed to redu
85. s See your authorized Polaris ATV dealer for more information 4 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 THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow a greater distance for braking Always follow the instructions in the owner s manual for carrying cargo or pulling a trailer See page 54 4 amp 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 31 SAFETY Operator Safety A A 32 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 o
86. se oil as needed to bring the level to the bottom of the fill hole threads 4 Reinstall the fill plug Torque to specification Oil Change 1 Position the vehicle on a level surface and remove the fill plug 2 Place a drain pan beneath the gearcase remove the gearcase drain plug 3 located on the bottom right hand side and drain the oil 3 Clean and reinstall the drain plug Torque to specification 4 Add the recommended fluid 5 Reinstall the fill plug Torque to specification 6 Check for leaks 77 MAINTENANCE AND LUBRICATION Transmission Oil Always check and change the T transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 69 Maintain the transmission oil level at the bottom of the fill plug hole 1 Refer to the Gearcase Specifications Chart on page 80 for recommended lubricants capacities and torque specifications See page 114 for the part numbers of Polaris products The transmission oil fill plug 2 is located on the right side of the ATV ue behind the footwell The transmission drain plug 3 is located on the bottom left hand side of the gearcase Oil Check 1 Remove the footwell see page 86 2 Remove the fill plug and check the oil level 3 Reinstall the fill plug Torque to specification 4 Reinstall the footwell Oil Change 1 Remove the footwell see page 86 2 Remove the drain plug and drain the oil into a
87. sign 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 TABLE OF CONTENTS WELCOME aber tet tines LE UE Eie 3 VEHICLE IDENTIFICATION NUMBERS 7 SAFETY uteri d eee Ea anri itis EE p Es 8 CONTROLS quebec ned eut tei ent 33 FEATURES LIRWERSAMESA 41 OPERATION ust TEE MUERE terre RS 49 EMISSION CONTROL SYSTEMS 68 MAINTENANCE AND LUBRICATION 69 ADJUSTMENTS i 2 ieslkkwee kx Es ERE ss 109 SPECIFICATIONS 112 POLARIS 5 114 TR
88. tact 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 3 mm will remain at the rear bolts 109 ADJUSTMENTS Carburetor Idle RPM 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 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 with the parking brake applied 3 Adjust the carburetor idle screw 1 either in or out until the desired idle RPM is reached Turning the screw in clockwise will raise RPM Turning the screw out counterclockwise will lower RPM NOTE Continuous operation of the engine without proper jet
89. ter should be replaced by your dealer after every 100 hours of operation or annually Do not attempt to clean the fuel filter 39 CONTROLS Automatic Transmission Gear Selector The transmission gear selector 1 is located on the right side of the vehicle H High Gear L Low Gear N Neutral R Reverse P Park UD zr I 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 PARK and lock the parking brake Belt Life To extend belt life use low forward gear in heavy pulling situations and when operating at less than seven miles per hour for extended periods of time 40 FEATURES 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 Polaris 4 cycle engines are equipped with automatic decompressors This makes recoil starting possible by reducing the amount of compression during starting The decompressor senses when the engine is spinning fast enough to start and restores compression when running 1 Position the vehicle on a level surface and lock the parking brake see page 37
90. tered 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 procedure 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 described in this manual 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 16 SAFETY Operator Safety Wet brakes may have reduced stopping ability Test the brakes after leaving water If necessary apply them lightly several times to allow friction to dry out the pads Always check for obstacles or people
91. th 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 Operating this ATV if you are under the age of 16 increases your chance of severe injury or death N ST E P NEVER operate this ATV if you are 7172563 under age 16 7172559 AWARNING DONOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death Tow only from tow hooks or hitch Max Rack Loads Front 150 Ibs 68 kg Rear 300 Ibs 136 kg 7172927 10 SAFETY Safety Decals and Locations A WARNING ALL WHEEL Pushing reverse DRIVE override button SWITCH may cause sudden increases in power and Do not push switch to traction if too engage AWD if the rear much throttle is wheels are spinning applied Loss of This may cause severe control or forward drive shaft and clutch flipover may damage result especially See your Owner s in AWD See Manual Owner s Manual 7172564 7079780 MANUFACTURED BY POLARIS IND INC DATE VIN THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS CE V HICULE EST UN V HICULE TOUT TERRAIN QUI N EST PAS DESTIN TRE UTILIS SUR LES CHEMINS PUBLICS PATENT NOTICE Mfd by All Terrain Vehicle Division Polaris Industries Inc under one or more of the following patents Other patents pending U S Patents 4697665 50
92. ting 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 110 ADJUSTMENTS 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 1 5 3 mm 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 1 111 SPECIFICATIONS Sportsman MV7 weight not to exceed 300 Ibs 136 kg 112 SPECIFICATIONS Sportsman MV7 Shift Type Gear Reduction Low Gear Reduction Reverse Gear Reduction High Drive Ratio Front Drive Ratio Final Tire Size Front Tire Size Rear Front Brake Rear Brake Parking Brake Front Suspension Rear Suspension Shock Adjustment Headlight Taillights Brake Light Instrument Cluster Jetting Chart AMBIENT Altitude TEMPERATURE Meters 0 1800 Feet 0 6000 1800 3700 6000 12000 Clutching Chart Altitude Meters 0 1800 Feet 0 6000 1800 3700 6000 12000 Shift Weight 20 56 PN 5631215 20 54 PN 5631214 EBS models require no helix spring adjustment Side Lever H L N
93. tio difference between high and low range is 1 2 25 This difference in gearing affects the operation of the PVT especially at speeds less than 7 MPH 11 KPH due to the system s dependence on engine speed For example when operating at a ground speed of 3 MPH 5 KPH in low range the engine speed would be around 3000 RPM This is well above the engagement speed of 1200 1400 RPM However in high range at 3 MPH 5 KPH the engine would be running at only 1500 RPM Whenever operating this close to the engagement speed the engine may be running at a speed too low to provide the pinch needed to prevent belt slip Belt slip is responsible for creating the excessive heat that destroys belts and causes outer clutch covers to fail By switching to low range while operating at low ground speeds the air temperature in the clutch cover is reduced by almost 160 degrees Reducing the temperature inside the clutch cover extends the life of the PVT components belt cover etc When To Use Low Range vs High Range Following is a guideline for when to use low range and high range Low Range When basic operation is at speeds less than 7 MPH 11 KPH For heavy pulling When operating in rough terrain swamps mountains etc at low ground speeds High Range When basic operation is at speeds greater than 7 MPH 11 KPH When operating at high ground speeds 98 MAINTENANCE AND LUBRICATION PVT System 4 WARNING Failure to comply
94. tlined 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 Belt Life Use low forward gear when hauling or towing heavy cargo to extend belt life 54 OPERATION Driving Safely 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 REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO CARGO WEIGHT DISTRIBUTION should be 1 3 on the front rack and 2 3 on the rear rack When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions Carrying loads on one rack only increases the possibility of vehicle overturn CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE Carrying loads high on the racks raises the center of gravity of the vehicle and creates a less stable operating condition e SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off center
95. to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas 49 OPERATION Break In Period The break in period for your new Polaris ATV is defined as the first ten hours of operation or the time it takes to use the first two full tanks of gasoline 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 50 CAUTION Excessive heat build up during the first three hours of operation will damage close fitted engine parts Do not operate at full throttle or high speeds for extended periods during the first three hours of use CAUTION Mixing brands or using a non recommended oil may cause serious engine damage We recommend the use of Polaris Premium 4 synthetic Oil or another OW 40 API certified SH oil Never substitute or mix oil brands Fill the fuel tanks with gasoline See page 39 Check the oil reservoir level on the dipstick See page 75 Add oil if necessary to maintain the level between the safe and add marks Drive slowly at first Select an open area that allows room to familiarize yourself with vehicle operation and handling Vary the throttle positions Do not operate at sustained idle Perform regular checks on fluid levels controls and areas outlined on the da
96. trical load lights cooling fan accessories is applied Driving at a higher RPM or connecting a battery charger will usually clear the warning 6 Odometer Tachometer Tripmeter Hour Meter 7 Fuel Gauge The segments of the fuel gauge indicate the level of fuel in the front tank only Since use of the rear tank is recommended for normal operation the rear tank may already be empty Refuel immediately if the last segment of the fuel gauge clears 8 Check Engine Warning Indicator The word HOT will display alphanumerically when the engine is overheating Do not continue to operate the ATV if this warning appears or serious engine damage could result 9 Mode Indicator s 45 FEATURES Instrument Cluster Rider Information Center The rider information center has 4 standard modes Mode 1 Odometer Mode 2 Tripmeter Mode 3 Total Service Hours Mode 4 Tachometer The reverse override button on the left handlebar is also the mode button NOTE If using the mode button to program the rider information center or to toggle through the options the machine cannot be in reverse Mode 1 Odometer The odometer records the miles traveled by the ATV Mode 2 Trip Meter The trip meter records the miles traveled by the ATV on each trip if it s reset before each trip To reset the trip meter select the trip meter mode Press and hold the mode button override button until the total changes to 0 NOTE In the Rider
97. ty oil designed to provide the ultimate in lubrication performance and protection NOTE See page 114 for the part numbers of Polaris products Premium 4 possesses unsurpassed film strength over the widest possible temperature range It resists viscosity and frictional breakdown in ambient temperatures from 40 F to 120 F 40 to 449 C Its exceptional frictional properties result in more efficient operation more power output and lower fuel consumption Although Polaris Premium 4 is the only oil recommended for use in this engine use of any API certified SH oil is allowable as long as it s OW 40 Oil may need to be changed more frequently if Polaris Premium 4 is not used Follow the manufacturer s recommendations for ambient temperature operation CAUTION Mixing brands or using a non recommended oil may cause serious engine damage We recommend the use of Polaris Premium 4 synthetic Oil or another OW 40 API certified SH oil Never substitute or mix oil brands 74 MAINTENANCE AND LUBRICATION Oil Check The dipstick oil fill 1 is located on the engine on the left side of the Do not start the engine before the oil check NOTE A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase If the oil level is over the full safe mark change the oil immediately 1 Position the vehicle on a level surface 2 Remove the dipstick and wipe it d
98. ug 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 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 rotate the spark plug counterclockwise to remove 3 Reverse the procedure for spark plug installation using the recommended spark plug Torque to 18 ft Ibs 24 Nm 94 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 1 2 NA RUD So 90 4 11 Move the ATV to dry land or at the very least to water below the footrests Check the air box for any water and dry it if water is present Filter replacement is required if water intrusion is evident Turn the fuel valve off Remove the spark plug Loosen the carburetor drain screw 1 Turn the engine over several times using the electric start Dry the spark plug and reinstall or replace it with a new plug
99. very bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the tank past the pressure cap and into the radiator NOTE Some coolant level drop on new machines is normal as the System is purging itself of trapped air Observe coolant levels and maintain as recommended by adding coolant to the recovery bottle 82 MAINTENANCE AND LUBRICATION 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 Toe Alignment 4 amp 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 Use the following procedure to check the toe alignment of the vehicle The recommended toe alignment is 1 8 to 1 4 3 6 mm toe out 1 Setthe handlebars in a straight ahead position 222 ou NOTE The steering frog can coer be used as an indicator 528 of whether the 5729 S e handlebars are straight The frog should always point straight back from the steering post 2 Place stands 1 in front of the vehicle perpendicular to the rear tires See illustration 3 Tiean elastic string around the stands making sure the string just touches the s
100. ws on the lower front corners of the headlight pod Remove the screw from the rear of the pod Lift the pod slightly while depressing the tabs at the rear of the pod Lift the pod cover and disconnect the speedometer harnesses from the speedometer Unplug the headlamp from the wiring harness Be sure to pull on the connector not on the wiring Turn the lamp counterclockwise to remove it Apply dielectric grease to the socket and install the new lamp NOTE Make sure the tab on the lamp locates properly in the 8 90 housing Reassemble the pod MAINTENANCE AND LUBRICATION Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward Use the following procedure to make the adjustment 1 Position the vehicle on a level surface with the headlight approximately 25 ft 7 6 m from a wall 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 3 Start the engine and turn the headlight switch to high beam 4 Observe the headlight aim on the wall The most intense part of the headlight beam should be two inches 5 1 cm below the mark on the wall NOTE Include rider weight on the seat when measuring 5 The adjustment knob is located on the right side of the headlight pod Adjust the beam to the desired position by turning the knob either clockwise or counterclockwise Low Beam Adjustment The low beam can be adjusted slight
101. ystem 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 Brake Fluid Level Check the brake fluid level frequently for the auxiliary brake system The reservoir is located under the seat or near the auxiliary brake Maintain the fluid level between the maximum and minimum marks 38 CONTROLS Choke The choke assists in starting a cold engine Refer to the engine starting procedure on page 52 for correct choke and throttle settings during starting Fuel Requirements Use either leaded or unleaded gasoline with a minimum pump octane number of 87 M 2 octane Fuel Valve The fuel valve 1 is located on the REAR left side panel TANK OFF Turn the fuel valve off for vehicle storage and when transporting OFF REAR TANK We recommend using the rear tank fuel supply first Switch to the front tank when the rear tank is empty It will be easier to monitor remaining fuel at the front tank gauge FRONT TANK Use the front tank fuel supply when the rear tank is empty NOTE There is no reserve fuel supply on this vehicle When both fuel tanks are empty the vehicle will not operate Fuel Tanks The front fuel tank filler cap 2 is located directly below the handlebar The rear fuel tank and filler cap 3 are located behind the seat under the rear rack Fuel Filter The in line fuel fil

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