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Polaris Sawtooth User's Manual

1. Adestasnesded p Perform these procedures more often for vehicles subjected to severe use E Emission Related Service m Have an authorized Polaris dealer perform these services 68 MAINTENANCE AND LUBRICATION Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 65 Items not listed in the chart should be lubricated at the General Lubrication interval omm w Engine Oil PS 4 0W50 See page 70 DOT 3 fluid only See page 39 Transmission Premium AGL Synthetic See page 74 Gearcase Lube Premium ATV Angle Drive See page 75 Fluid 1 Front A Arms e Grease Inspect tighten fasteners grease also after washing ATV or driving in water 69 MAINTENANCE AND LUBRICATION Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 65 Always change the oil filter whenever changing oil Performance Synthetic 4 Stroke PS 4 Oil Polaris recommends the use of Performance Synthetic 4 Stroke PS 4 0W50 oil for this engine PS 4 is a fully synthetic high performance multi viscosity oil designed to provide the ultimate in lubrication performance and protection See page 103 for the part numbers of Polaris products Oil may need to be changed more frequently if Polaris oil is not used Always use 0W50 oil Follow the manufacturer s
2. 2006 Sawtooth Owner s Manual for Maintenance and Safety Read this manual carefully It contains important safety i This is an adult vehicle only Operation is prohibited for those under 16 ye AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER Operate without proper training or instruction 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 e Avoid paved surfaces which may adversely affect handling and control e Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills and rough terrain and in turns e Wear eye protection helmet and protective apparel READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS p For your nearest Polaris dealer P sLARIS cai 1 800 POLARIS Toe Our or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 763 417 8650 Fax 763 542 0599 Part No 9920278 Printed in Taiwan and in USA 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 s
3. Avoid hazards such as logs rocks and low branches 4 WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle Not all obstacles are immediately visible Travel with caution in unfamiliar terrain BOUM 61 OPERATION Driving Safely Driving in Reverse Follow these precautions when operating in reverse 1 2 A Avoid backing downhill Always check for obstacles or people behind the vehicle before backing Drive slowly Apply the brakes lightly for stopping Avoid turning at sharp angles Never apply the throttle suddenly WARNING Failure to use caution when operating in reverse can result in serious injury or death Before shifting into reverse always come to acomplete stop and check for obstacles or people behind the vehicle When it s safe to proceed back slowly Avoid backing on inclines Avoid turning at sharp angles Do not use the override switch unless additional power is required for vehicle movement Use with caution NOTE The override switch should be used with caution as rearward 62 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 OPERATION Driving Safely Parking on an Incline
4. 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 18 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner s manual Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speed amp 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 19 SAFETY Operator Safety 4 WARNING 20 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 WARNING POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hill
5. Maintain proper tire pressure as described on the decal on your ATV and in the specifications section of the owner s manual beginning on page 100 Always use original equipment size and type when replacing tires Make sure the wheels are installed properly Always replace tires when the tread depth measures 1 8 3 cm or less Wheel Removal th REO por 92 Stop the engine Remove the key from the ignition Lock the parking brake Loosen the wheel nuts slightly Elevate the side of the vehicle by placing a suitable stand under the footrest frame Remove the wheel nuts and remove the wheel MAINTENANCE AND LUBRICATION Adjustments 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 Wheel Installation 1 Position the vehicle on a level surface 2 Lock the parking brake 3 Place the wheel on the wheel hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation 4 Install the wheel nuts and finger tighten 5 Lower the vehicle to the ground 6 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 Location
6. Break In 46 C Camber and Caster 88 Carburetor 90 Choke 43 Cleaning and Storage 96 99 Cleaning the ATV 96 Clutching 102 Cold Weather Operation 48 Constant Variable Transmission 81 Crankcase Emission Control System 64 E 81 CVT Drying 81 Driving Downhill 56 Driving in Reverse 62 Driving on Slippery Surfaces 54 Driving Over Obstacles 61 Driving Procedures 50 Driving Safely 50 63 Driving Through Water 60 Driving Uphill 55 E Electrical Switches 36 37 Emission Control Systems 64 Emissions Warranty 110 Engine Fogging 98 114 E Equipment Modifications 11 Exhaust Emission Control System 64 F Fogging 98 Foot Brake 41 Front Wheel Hub Tightening 94 Fuel Filter 0 0 0 0 eee 43 Fuel Safety 35 Fuel Stabilizer 97 FueLT nk v 43 Fuel Valve Re 43 G Gear 44 Gearcase Oil 75 Gearcase Specification Chart 74 H Handlebars 89 Hauling 52 53 Headlight Lamp Replacement 76 Helmet os koh inn AY RAE 34 1
7. Vehicle Model Number Frame VIN 1 Engine Serial Number 2 SAFETY Operator Safety 4 WARNING Failure to follow the warnings contained in this manual can result in serious injury or death A Polaris ATV is not a toy and can be hazardous to operate This vehicle handles differently than other vehicles such as motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions Read and understand your owner s manual and all warnings before operating a Polaris ATV Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age Safety Training safety training is a top priority for Polaris When you purchased your new ATV your dealer instructed you on the authorized ATV RiderCourse available to you and your eligible family members This training is included in the purchase price of your ATV Polaris strongly encourages you and your eligible family members who will be riding the ATV to take the ATV RiderCourse 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 you can take the ATV RiderCourse by calling ATV Enrollment Express at 800 887 2887 or by visiting www atvsafety org Purchasers of a used Polaris ATV will b
8. procedures exactly or see your Polaris dealer for service Handlebars The handlebars can be adjusted for rider preference 1 2 Loosen do not remove the 3 Remove the handlebar cover four handlebar bolts Adjust the handlebar to the desired height Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the B left or right Torque the front two bolts A to 10 12 ft Ibs 14 17 Nm then torque the rear two bolts B A gap of up to 1 8 3 mm will remain at the rear bolts 89 MAINTENANCE AND LUBRICATION Adjustments Carburetor IMPORTANT Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6 000 feet 1800 m and temperatures of 40 degrees F 4 degrees C or higher Above 6000 feet 1800 m the engine air fuel mixture becomes overly rich and the engine loses approximately 3 of its power for each 1000 foot 304 8 m increase in elevation Although this power cannot be regained adjustments to the carburetor and drive system can be made to allow more efficient operation Optional jets available from your Polaris dealer are required for operation above 6 000 feet and temperatures below 40 degrees F 4 degrees C NOTE Continuous operation of the engine without proper jetting when required can cause poor performance overheating or engine damage See your Polaris dealer for more information about jett
9. 2871312 2871329 103 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 8 VDC Loose solenoid connections Check all connections and tighten Engine Turns Over Fails to Start Possible Cause Solution Turn fuel valve to reserve refuel 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 104 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 Fuel Mixture Cause Solution Possible Rich Fuel Mixture Cause Solution 105 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 ba
10. 3 Inspect the screen for wear and damage Replace if necessary 4 Remove and inspect the gasket Replace if worn or damaged 5 Reinstall the gasket and arrestor 6 Torque screws to 50 in Ibs 5 6 Nm 80 MAINTENANCE AND LUBRICATION Constant Variable Transmission CVT System 4 amp WARNING Failure to comply with the instructions in this warning can result in severe injury or death Do not modify any component of the CVT system Doing so may reduce its strength so that a failure may occur at a high speed The CVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The CVT 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 CVT system is intended for use on Polaris products only Do not install it in any other product Always make sure the CVT housing is securely in place during operation CVT Drying There may be some instances when water is accidently ingested into the CVT system Use the following instructions to dry it out before operating The drain plug is located on the bottom of
11. Do not exceed the maximum capacities when towing Do not tow any trailer on a grade steeper than 15 Maximum Towed Load Maximum Vertical Hitch Level Ground Weight 300 Ibs 136 kg 30 Ibs 13 6 kg 52 OPERATION Driving Safely Hauling Cargo and Towing 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 SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme
12. Indicator 37 Jetting Chart 102 K K T rn 4 ERR 58 59 Key Switch 36 Kick Start Lever 45 L Light Switch 36 Lights ee j de seo 76 77 Lubrication Guide 69 M Main Switch 36 Maintenance Log 111 113 Making Turns 51 Master Cylinder 39 N Noise Emission Control System 64 Oil Change 72 73 Oil Check re 71 Oil Engine ars enine RAS 70 Operator 5 6 29 Override Switch 37 P Parking Brake 42 Parking an Incline 63 Periodic Maintenance Chart 65 68 Polaris Products 103 Pre Ride Inspection 47 R Rear Gearcase Oil 75 Rear 88 S Safe Riding 34 Safety Decals and Locations 30 33 Safety Training 6 Severe Use 65 Side Panel Removal 91 Sidehilling 57 Spark Arrestor Clean Out 80 Spark 78 Specifications 100 102 S Start 36 Starting the Engine 48 49 Steering Assembly 88 Stop 36 Storage Tips 97 98 T Taillight Brak
13. LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CON TRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE Some states do not per mit the exclusion orlimitation 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 107 WARRANTY WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES ALLIMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THEIMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRAN TY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an im plied warranty lasts so the above limitation may not apply to you if inconsistent with con trolling state law HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service you must take it to a Polaris dealer authorized to re pair Polaris ATVs When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform war ranty service Please work with your dealer t
14. Specification Front Wheel Nuts 27 ft Ibs 37 Nm Rear Wheel Nuts 27 ft Ibs 37 Nm 93 MAINTENANCE AND LUBRICATION Adjustments Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations All service must be performed by your authorized Polaris dealer Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less See illustration 4 amp WARNING Operating the vehicle with worn tires will increase the possibility of skidding AN which could lead to loss of control and serious injury or death Always replace tires when the tread depth measures 1 8 3 mm or less 4 WARNING Use of non standard size or type of tires or improper tire inflation may adversely affect vehicle maneuverability and cause loss of control resulting in serious injury or death Maintain proper tire pressure as outlined in this owner s manual When replacing a tire always use original equipment size and type 1 8 3 mm 94 MAINTENANCE AND LUBRICATION Adjustments Air Filter Service 1 2 3 Remove the seat Release the clips and remove the air box cover A Loosen the clamp and remove the filter Remove the pre filter B from the main filter C 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 b
15. 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 Cg 15 SAFETY Operator Safety 4 WARNING 16 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 WARNING POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Attempting stunts increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt wheelies jumps or other stunts Avoid exhibition driving SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV before e
16. 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 SAFETY Operator Safety Always travel slowly and use extra caution when operating 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 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 ascend a hill Never climb hills with excessive ly slippery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes Never go over the top of a hill at high speed Always follow proper procedures for going downhill and for braking on hills Check the terrain carefully
17. assembly from the vehicle To access the headlight assembly without removing the front cover reach up under the front cab 1 Remove the rubber cover A from the back of the headlight 2 Rotate the socket B counterclockwise and pull it away from the headlight assembly 3 Remove the headlamp Install the new headlamp B 5 Reinstall all components 76 MAINTENANCE AND LUBRICATION Lights Taillight Brakelight Lamp Replacement If the taillight brakelight does not work the lamp may need to be replaced 1 Remove the taillight lens B A cover mounting screws A d zi p A 2 Remove the lens 45 cover and set aside 22 for reassembly 3 Remove the lamp B 4 Apply dielectric grease to the socket and install a new lamp 5 Test the taillight brakelight for proper operation 6 Reinstall the lens cover 77 MAINTENANCE AND LUBRICATION Spark Plugs Refer to the specifications section beginning on page 100 for spark plug and gap specifications 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 protecti
18. 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 53 OPERATION Driving Safely Driving on Slippery Surfaces Whenever driving on slippery or loose surfaces such as wet trails gravel snow or ice follow these precautions 1 Slow down before driving onto slippery surfaces 2 Use extra caution 3 Bealert Watch the trail Avoid quick sharp turns NOTE correct a rear wheel skid turn the handlebars in the same direction as the skid and shift body weight forward 4 WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control accident and serious injury or death Never apply the brakes during a skid Do not operate on excessively slippery surfaces Always reduce speed and use additional caution 54 OPERATION Driving Safely Driving Uphill When
19. in forward 7172665 Ne jamais conduire ce VTT sur des pentes plus de 25 degr s Pour viter un retournement lors de mont e ou de la descente de pentes utiliser les freins et l acc t rateur graduellement La conduite en MARCHE ARRIERE peut tre dangereuse m me basse vitesse Le braquage est plus difficile Pour viter le retournement viter les freinages brusques et les virages serr s Le FREIN DE STATIONNEMENT peut se desserrer s il reste engag pendant plus de 5 minutes Lors du stationnement sur une pente engager la marche avant 7172665 SAFETY Safety Decals and Locations AWARNING Os Operating this ATV if you are under the age of 16 increases your chance of severe injury or death NEVER operate this ATV if you are under age 16 7172559 AWARNING Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death NO STEP 7173313 AWARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH 7172566 SAFETY Safety Decals and Locations AWARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE IN PSI KPa FRONT 4 27 6 REAR 3 20 7 MAXI
20. least to water below the footrests Check the airbox for any water and dry it if water is present Turn the fuel valve off Remove the spark plug Loosen the carburetor drain screw A Turn the engine over several times using the electric start Dry the spark plug and reinstall or replace it with a new plug 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 transmission follow the procedure on page 81 for drying the CVT 79 MAINTENANCE AND LUBRICATION Spark Arrestor Clean Out 4 WARNING Do not perform clean out immediately after the engine has been run as the exhaust system becomes very hot Serious burns could result from contact with the exhaust components Wear eye protection and gloves Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas Failure to heed these warnings could result in serious injury or death Periodically clean the spark arrestor to remove accumulated carbon 1 Remove the three screws A and remove the arrestor from the end of the muffler 2 Usea non synthetic brush to clean the arrestor screen A synthetic brush may melt if components are warm If necessary blow debris from the screen with compressed air
21. start lever on the left side of the ATV Make sure the stop switch and main key switch are on Place your foot on the kick start Thrust your heel downward to crank the engine NOTE Ifthe engine is cold use the choke as outlined on page 48 4 After the engine has started fold the kick start lever back into place NOTE A 10 12 mm wrench is provided in the tool kit for removing or installing the lever If not installed make sure the rubber cap is installed on the kick start shaft to protect the rider Store the kick start lever under the seat in the rear cab when not installed 45 OPERATION Break In Period The break in period for your new Polaris 4 cycle 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 46 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 Never substitute or mix oil brands Fill the fuel tank with gasoline See page 43 Check the o
22. the CVT cover 1 2 3 Remove the drain plug Allow the water to drain Reinstall the drain plug Place the transmission in neutral Start the engine 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 Test for belt slippage If the belt slips repeat the process Take the vehicle to your dealer for service as soon as possible 81 MAINTENANCE AND LUBRICATION Battery 4 amp WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last Battery Removal 1 Remove the seat 2 Disconnect the battery hold down strap 3 Disconnect the black negative battery cable first 4 Disconnect the red positive battery cable next 5 Lift the battery out of the battery compartment Battery Installation When installing a new battery make sure it s fully charged prior to its initial use Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance Follow the battery charging instructions on page 83 before installing the battery 1 Ensure that the battery
23. warm up then shift the transmission into gear Check your surroundings and determine your path of travel Slowly squeeze the throttle lever toward the handlebar to begin driving Squeeze the throttle lever further to increase speed Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces OPERATION Driving Safely Making Turns 1 To make a turn steer in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest Use the same leaning technique for turning in reverse 2 Practice turning at slow speeds before attempting to turn at faster speeds 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 51 OPERATION Driving Safely Hauling Cargo and Towing 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 outlined in the specifications section of the owner s manual and on the safety decals Cargo weight should be evenly distributed 1 3 on the front rack and 2 3 on the rear rack and mounted as low as possible When operating over rough or hilly terrain reduce speed and cargo weight to maintain stable driving conditions Do not obstruct the headlight beam with cargo
24. ARD 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 WARNING POTENTIAL HAZARD Operating this ATV on public streets roads or highways WHAT CAN HAPPEN The ATV could collide 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 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet eye protection and protective clothing WHAT CAN HAPPEN 1 Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an 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 4
25. Avoid parking on an incline If it s unavoidable follow these precautions 1 1 2 3 Turn the engine off Place the transmission in gear and lock the parking brake Always block the rear wheels on the downhill side Turn the fuel valve off 63 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine intake or exhaust components as doing so may affect compliance with U S A EPA noise control requirements 40 CFR 205 and local noise level requirements Operation on Public Lands in the U S A Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100 1C Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public lands in the U S A is regulated by 43 CFR 8343 Violations are subject to monetary penalties Federal regulations can be viewed online at WWw gpoaccess gov ecfr Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system exhaust gases exit through the exhaust system 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 spec
26. Daily Check level daily change if applicable coolant every 2 years Headlamp tail Daily Check operation apply lamp dielectric grease if replacing Air filter Weekly Inspect replace as needed main element Recoil housing Weekly Drain water as needed if equipped check often if operating in wet conditions H Brake pad wear Monthly 100 160 Inspect periodically 20H Monthly 200 320 Check terminals clean test Front gearcase oil 25 H Monthly 250 400 Inspect level change yearly if equipped Rear gearcase oil Monthly 250 400 Inspect level change yearly if if equipped Monthly 250 400 Inspect level change yearly us breather 25H Monthly 250 400 Inspect clean if needed filter if equipped p Perform these procedures more often for vehicles subjected to severe use E Emission Related Service m Have an authorized Polaris dealer perform these services 66 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Interval whichever comes first Calendar Miles Km 3M 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 6M 500 800 Inspect adjust replace as needed 1000 1600 Inspect coolant strength seasonally pressure t
27. ION 3 6 Hot oil can cause serious burns to skin Do not allow hot oil to come into contact with skin Place a drain pan beneath the engine crankcase and remove the drain plug Allow the oil to drain completely Install a new sealing washer on the drain plug NOTE The sealing surfaces on the drain plug and crankcase should 72 be clean and free of burrs nicks or scratches MAINTENANCE AND LUBRICATION Oil and Filter Change 7 8 10 11 12 13 14 15 16 17 Reinstall the drain plug Torque to 11 ft Ibs 15 Nm Place shop towels beneath 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 gasket on the new filter with a film of engine oil Check to make sure the gasket 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 oil fill plug and add the recommended oil Refer to the specifications section beginning on page 100 for capacities Do not overfill Reinstall the fill plug Start the engine and let it idle for one to two minutes Stop the engine and inspect for leaks Check the oil level and add oil as necessary to maintain the level at the center of the sight glass Dispose of used filter and oil properly 73 MAINTENANCE AND L
28. Indicator lights switches Engine stop switch Air filter pre filter Ensure proper operation Ensure operation Cc Ensure proper operation Inspect clean Air box sediment tube Headlamp Drain deposits whenever visible Check operation apply dielectric grease when lamp is replaced Check operation apply dielectric grease when lamp is replaced Wear helmet goggles protective clothing N o Brake light tail lamp Riding gear A Co N 47 OPERATION Cold Weather Operation for 4 Cycle Engines Internal engine condensation increases as outside temperatures decrease If the vehicle is used year round check the oil level frequently A rising oil level could indicate condensation in the bottom of the crankcase which can lead to engine damage Any condensation must be drained If the oil level rises to the top of the sight glass change the oil immediately Always operate the engine long enough to reach operating temperature which reduces condensation Starting the Engine 4 WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death Never run an engine in an enclosed area Position the vehicle on a level surface Turn the fuel valve on Sit on the vehicle If the engine is cold use full choke by pushing the choke lever A all the way to the left A warm engine will not require the use of the choke NOTE The
29. MUM WEIGHT CAPACITY Gross Vehicle Weight INCLUDING MACHINE DRIVER AND CARGO IS 765 LBS 348 KG Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your risk of losing control Loads should be centered carried as low as possible and firmly secured to the racks With dual racks load distribution 1 3 front 2 3 rear is best For stability on rough or hilly terrain reduce speed and cargo Do not block headlight Be careful if load extends over the side of the rack Read Owner s Manual for more detailed loading information 7172664 Operation of this vehicle Specific without the air filter carburetor jetting element will severely damage and adjustments are required the engine depending on temperature Clean pre filter element often and altitude See your Owner s more frequent cleaning Manual required in dusty conditions Factory setting Do not operate vehicle without 40 to 80 F at 0 3000 feet pre filter 5 to 27 C at 0 900 meters 7170007 AWARNING DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death Tow only from tow hooks or hitch Max Rack Loads Front 45 Ibs 20 kg Rear 70 Ibs 32 kg 7173909 32 Safety Decals and Locations A WARNING Improper ATV use can result in SEVERE INJURY or DEATH DOG ALWAYS USE NEVER USE NEVER CARRY NEVER USE A
30. N APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control 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 MANUFACTURED SAFETY IN TAIWAN OVERRIDE SWITCH Reverse Speed is limited Reverse override is 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 controlled by the override switch See your Owner s Manual 7079906 33 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
31. Purchased From A Private Party If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased all warranty coverage will be denied Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ranty or service bulletin coverage of any kind Vehicles registered to Government offi cials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions call Polaris Customer Assistance United States 1 763 417 8650 Canada 1 204 925 7100 109 WARRANTY U S A EPA Emissions Limited Warranty This Terrain Vehicle or Off Road Utility Vehicle ORUV emissions limited warranty is in addition to the Polaris standard limited warranty for this vehicle Polaris warrants that this vehicle is 1 designed built and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and 2 free from defects in materials and workmanship that may keep it from meeting these requirements The emissions warranty period for this vehicle begins on the date the vehicle is delivered to the original retail purchaser and ends 30 months 2 5 years after that date or after 5000 km 3100 miles whichever comes first This emission related warran
32. UBRICATION Gearcase Specification Chart Gearcase Lubricant Capacity Drain Check Fill Plug Plug Torque Torque Transmission Premium AGL Synthetic 18 6 oz 18 ft Ibs N A Gearcase Lubricant 550 ml 24 Nm Rear Premium ATV Angle 4 oz 18 ft Ibs 25 ft Ibs Gearcase Drive Fluid 120 ml 24 Nm 84 Nm Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 65 Maintain the oil level between 1 4 and 3 4 on the sight glass We recommend the use of Premium AGL Synthetic Gearcase Lubricant Refer to the gearcase specifications chart on page 74 See page 103 for the part numbers of Polaris products Cil Check 1 Position the vehicle on a level surface 2 View the oil level through the sight glass A 3 Remove the fill plug B and add the recommended oil as needed 4 Reinstall the fill plug Oil Change The transmission drain plug is located on the bottom of the vehicle near the center 1 Remove the fill plug 2 Remove the transmission drain plug Drain the oil into an appropriate container Discard used oil properly 3 Clean and reinstall the drain plug Torque to specification 4 Add the recommended fluid 5 Reinstall the fill plug 6 Check for leaks MAINTENANCE AND LUBRICATION Rear Gearcase Oil Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginni
33. ach 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 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 17 SAFETY Operator Safety 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 HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions 4 WARNING POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough slippery or loose terrain WHAT CAN HAPPEN Operating on excessively rough slippery 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
34. 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 Maintenance Chart Key p Perform these procedures more frequently for vehicles subjected to severe use E Emission related service Failure to conduct this maintenance will not void the emissions warranty but may affect emissions 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 65 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 be a i Make adjustments as need a enin ch T cl Eie een n un uec a co il pro n uh prep Air filter pre filter Daily Inspect clean often replace as needed Air box sediment Daily Drain deposits when visible tube Coolant
35. arward 3 Slow down 4 Never go down a hill at high speed 5 Squeeze the left hand rear brake lever slightly to aid in slowing Do not apply the front brakes 6 Avoid hills with excessively slippery or loose surfaces 7 Avoid going down a hill at an angle which can cause the vehicle to pitch sharply to one side NOTE Familiarize yourself with operation of the rear foot brake 4 WARNING Excessive speed can cause loss of control and lead to serious injury or death Always operate slowly when traveling downhill 56 OPERATION Driving Safely Sidehilling WARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn resulting in severe injury or death Avoid crossing the side of a hill when possible Follow proper procedures as outlined in the owner s manual Avoid crossing the side of a hill sidehilling if possible If sidehilling is necessary follow these precautions Avoid hills with excessively slippery or loose surfaces Avoid crossing the sides of steep hills Slow down Shift your weight uphill Keep your feet on the footrests Steer slightly into the hill Qv gods p NOTE Ifthe vehicle begins to tip quickly turn the front wheels downhill if possible or dismount on the UPHILL side immediately 57 OPERATION Driving Safely Turning Around on a Hill 4 WARNING Improper hill climbing procedures could cause loss of control or ove
36. astic string around the stands making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in front of the vehicle B 4 Measure the distance from the string to the rim at the front and rear of the front rim C Rear measurement should be 1 16 1 8 2 3 mm more than the front measurement D 20 US xd fe 1 Ke NOTE f you discover improper alignment see your Polaris dealer for service 87 MAINTENANCE AND LUBRICATION Adjustments Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts If loose nuts and bolts are found see your Polaris dealer for service before operating the vehicle Camber and Caster The camber and caster are non adjustable Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster A either clockwise or counterclockwise to increase or decrease spring tension NOTE Accessory springs are available through your Polaris dealer 88 MAINTENANCE AND LUBRICATION Adjustments 4 amp 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
37. ating 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 Wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them lightly several times to allow friction to dry out the pads Always check for obstacles or people behind the ATV before operat ing in reverse When it s safe to proceed in reverse move slowly and avoid turning at sharp angles Always use the size and type of tires specified for your ATV and always maintain tire pressure as recommended SAFETY Operator Safety 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 Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting FOR MORE INFORMATION ABOUT ATV SAFETY call the Consumer Product Safety Commission at 1 800 638 2772 or visit www cpsc gov visit www atvsafety org or call Polaris at 1 800 342 3764 Equipment Modifications We are concerned for the safety of our customers and for the general public The
38. before you start down a hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when pos sible Always follow proper procedures for crossing the side of a hill Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV Never attempt to turn the ATV around on any hill until you ve mastered on level ground the turn ing technique outlined in this manual Avoid crossing the side of a steep hill when possible SAFETY Operator Safety 10 Always use proper procedures if you stall or roll backwards while climbing a hill To avoid stalling maintain a steady speed when climbing a hill If you stall or roll backwards follow the special pro cedure for braking described in this manual Always dismount on the uphill side or to either side if the ATV is pointed straight uphill Turn the ATV around and remount following the procedure de scribed in this 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 oper
39. choke is fully on when the lever is pushed completely to the left The choke is off when the lever is pushed completely to the right The choke can be adjusted gradually depending on how much choke is needed for starting 5 Place the engine stop switch in the ON position then turn the main key switch on NOTE Do not press the throttle while starting the engine 48 OPERATION Starting the Engine 6 Squeeze the left brake lever NOTE The starter will not engage unless the rear brake is applied 7 8 10 Always squeeze and hold the left brake lever before attempting to start the engine Press the start button Activate the starter for a maximum of five seconds releasing the button when the engine starts If it doesn t start release the starter wait five seconds then activate for another five seconds Repeat until the engine starts If the engine slows or stops position the choke lever half way to allow proper engine warm up Vary the RPM slightly with the throttle to aid in warm up When the engine idles smoothly push the choke lever all the way to the right CAUTION Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle 49 OPERATION Driving Safely Driving Procedures 50 Sit upright Keep your feet on the footrests Keep both hands on the handlebars Start the engine and allow it to
40. dure described in the owner s manual See page 58 23 SAFETY Operator Safety 4 WARNING 24 POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Awoid operating over large obstacles such as rocks and fallen trees when possible If unavoidable use extreme caution and always follow proper procedures as outlined in the owner s manual WARNING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Skidding or sliding can cause loss of control 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 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Operating the ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident or overturn HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast flowing water If it s unavoidable to enter water that exceeds the recommended maximum depth see page 60 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 mak
41. e charged for this training A Polaris ATV is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area We strongly advise you to strictly follow the recommended maintenance program outlined in your owner s manual This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals SAFETY Operator Safety Know Your Vehicle and Riding Area You are responsible for your personal safety the safety of others and the protection of the environment Read and understand your owner s manual It includes important information about Quadricycle safety Ride responsibly Know all laws and regulations concerning the operation of this vehicle in your area Signal Words and Symbols The following signal words and symbols appear throughout this manual and on your ATV Your safety is involved when these words and symbols are used Become familiar with their meanings before reading the manual A The safety alert symbol on your vehicle or in this manual alerts you to the potential for personal injury 4 WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death 4 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 r
42. e 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 25 SAFETY Operator Safety 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 come to a complete stop and check for obstacles or people behind the ATV When it s safe to proceed back slowly 4 WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires or operation of the ATV with improper or uneven tire pressure could cause loss of control or accident HOW TO AVOID THE HAZARD Always use the size and type of tires specified for the ATV Always maintain proper tire pressure as specified 26 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Operating the ATV with improper modifications WHAT CAN HAPPEN c 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 compo
43. ed right to your door POLARIS The Way Out Copyright 2005 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 Taiwan and in U S A 2006 Sawtooth Owner s Manual P N 9920278 2 TABLE OF CONTENTS VEHICLE IDENTIFICATION NUMBERS 4 SAFELY P EvEve 5 FEATURES AND CONTROLS 36 OPERATION 46 EMISSION CONTROL SYSTEMS 64 MAINTENANCE AND LUBRICATION 65 SPECIFICATIONS 100 POLARIS PRODUCTS 103 TROUBLESHOOTING 104 WARRANTY 107 MAINTENANCE LOG 111 INDEX zc tado vos dtes Doe eun 114 VEHICLE IDENTIFICATION NUMBERS Record your ATV s identification numbers in the spaces provided Remove the spare key and store it in a safe place If both keys are lost the ignition switch must be replaced
44. elight Lamp Replacement 77 Throttle Cable Freeplay 91 Throttle 38 Tire Tread Depth 94 Toe Alignment 87 TOWING eee he oe a tk 52 53 Transmission Gear Selector 44 Transmission 74 Transporting an ATV 99 Troubleshooting 104 106 Turning Around ona Hill 58 59 V Vehicle Identification Numbers 5 Vehicle Immersion 79 W Warranty 4s cete Ek 107 110 Washing the ATV 96 Waxing the 96 Wheel Installation 93 Wheel Nut Torque Specifications 93 Wheel Removal 92 115
45. elow the handlebar Use either leaded or unleaded gasoline with a minimum pump octane number of 87 M 2 octane Refer to the specifications section beginning on page 100 for tank capacity Fuel Valve The fuel valve B is located on the left side of the vehicle OFF Turn the valve off before storage and when transporting ON Turn the valve on for normal operation RES Turn the valve to the reserve setting if the main fuel supply is exhausted Refuel as soon as possible Reserve fuel range is about 7 10 miles 11 16 km NOTE Return the valve to the ON position after refueling 43 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector A is located on the right side of the vehicle F Forward Gear N Neutral R Reverse Whenever the ATV is left unattended always place the transmission in gear and lock the parking brake 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 44 FEATURES AND CONTROLS Kick Start Lever If the battery becomes too weak to start the engine use the kick start lever to start the engine until the battery is serviced 1 WN t p Position the vehicle on a level surface Lock the parking brake Place the transmission in neutral Fold out the kick
46. ent Express at 800 887 2887 or visit www atvsafety org 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 Carrying a passenger greatly reduces the operator s ability to balance and control the ATV which could cause an accident and injury to the 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 Carrying a passenger on one of the racks WHAT CAN HAPPEN A passenger riding on a rack could be ejected from the vehicle unexpectedly or may contact moving components both of which can result in severe injury or death HOW TO AVOID THE HAZARD Never allow passengers to ride on one of the racks 13 SAFETY Operator Safety 4 WARNING 14 POTENTIAL HAZ
47. er 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 58 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 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Stalling rolling backwards or improperly dismounting while climbing a hill WHAT CAN HAPPEN The vehicle could overturn HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill If all forward speed is lost Keep your weight uphill Gradually apply the front brakes right lever When fully stopped apply the rear brakes and lock the parking brake Dismount on uphill side or to either side if ATV is pointed straight uphill Turn the ATV around and remount following the procedure described in the owner s manual See page 58 If the ATV begins rolling backwards Keep weight uphill Apply the front brake gradually Never apply the rear brake while rolling backwards Never apply engine power When fully stopped apply the rear brake as well and then lock the parking brake Dismount on uphill side or to either side if ATV is pointed straight uphill Turn the ATV around and remount following the proce
48. est system yearly General lubrication Carburetor float bowl Throttle Cable ETC Switch ES Carburetor air intake ducts flange Cooling system if applicable Engine oil change 100 H Oil filter change 100 H 1000 1600 Perform a break in oil change at one month 1000 1600 Replace with oil change 1000 1600 Inspect adjust 1000 1600 Check for leaks at tank cap lines fuel valve filter pump carburetor replace lines every two years 1000 1600 Inspect clean external surfaces 1000 1600 Inspect for leaks 3900 800 pipe Spark plug 100 H 1000 1600 Inspect replace as needed ton Ting 7007 TODO 1600 p Perform these procedures more often for vehicles subjected to severe use E Emission Related Service m Have an authorized Polaris dealer perform these services 67 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Interval whichever comes first 28 Miles Km Wiring 100 lal 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc drive 100 H 1000 1600 Inspect clean replace worn ms don parts Front wheel 100 H 1000 1600 Inspect replace as needed bearings m Brake ua 24M 000 6200 Change every wo years Saares sew 3000 0800 Cleanout _ esea O O OO en Toe adjustment Inspect periodically adjust eee lineman Readightaim
49. esult in damage to the vehicle NOTE 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 proper instruction 7ake a training course Purchasers of a new Polaris ATV and their eligible family members are entitled to take the ATV RiderCourse Contact ATV Enrollment Express at 800 887 2887 or visit www atvsafety org for information on enrollment in the ATV RiderCourses 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
50. et 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 WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any ATV that has been al tered structurally modified neglected improperly maintained used for racing or used for purposes other than for which it was manufactured or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addi tion this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the ATV due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the ATV The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO
51. ever traveling uphill follow these precautions S 1 Drive straight uphill 2 Avoid steep hills 25 maximum 3 Avoid hills with excessively slippery or loose surfaces 4 Keep your feet on the footrests 5 Shift your weight uphill 6 Drive at a steady rate of speed to avoid stalling 7 Bealert Be prepared to take emergency action This may include dismounting quickly 8 Never go over the top of a hill at high speed If all forward speed is lost 1 Keep your weight uphill NOTE fthe vehicle begins rolling downhill never apply engine power Never apply the rear brakes while rolling backwards 2 Gradually squeeze the right hand brake lever to engage the front brakes When fully stopped apply the rear brake as well then lock the park brake 3 Dismount on uphill side or to either side if ATV is pointed straight uphill Turn the ATV around and remount following the procedure described on page 58 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 55 OPERATION Driving Safely Driving Downhill Whenever descending a hill follow these precautions 1 Drive straight downhill 2 Shift your weight re
52. exceeds your state s safety standards and bears either the Department of Transportation DOT label the American National Standards Institute label ANSI z90 1 or the Snell Memorial Foundation label 2 Eye Protection Do not depend on sunglasses for proper eye protection A pair of goggles or a helmet face shield offer the best protection for your eyes They should be kept clean and be of shatterproof design bearing the markings z2 1 or VESC 8 3 Gloves Off road style gloves with knuckle pads are the best for comfort and protection 4 Boots The best footwear is a pair of strong over the calf boots with heels like moto cross boots 5 Clothing Always wear long sleeves and long pants to protect arms and legs Riding pants with kneepads and a jersey with shoulder pads provide the best protection 34 SAFETY Fuel Safety 4 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 ex
53. g only one brake could cause loss of control and result in serious injury or death Always apply both brakes at the same time Brake Lever Right 1 Squeeze the right brake lever 1 b toward the handlebar to apply the hydraulic front wheel brakes THIS LEVER DOES NOT APPLY THE REAR BRAKES 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 Always test front brake lever travel and master cylinder fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before riding Contact your dealer for proper diagnosis and repairs Brake Lever Left Squeeze the left brake lever 2 toward the handlebar to apply the mechanical rear wheel brakes THIS LEVER DOES NOT APPLY THE FRONT BRAKES 40 FEATURES AND CONTROLS Brakes Foot Brake The foot brake 1 is a mechanical rear wheel brake The foot brake is located on the inside of the right footrest Apply the brake with your right foot This is identical to squeezing the left brake lever on the handlebar NOTE Ifthe rear wheels slide while using the foot brake reduce brake pedal pressure to brake the rear wheels without skidding 4 amp WARNING Aggressively applying the rear brake when backing down a hill may cause rea
54. g strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher 2 Ifthe voltage is less than 12 8 volts recharge the battery at 1 2 amps or less until the battery voltage is 12 8 or greater NOTE When using an automatic charger refer to the charger manufacturer s instructions for recharging When using a constant current charger use the following guidelines for recharging 4 amp WARNING An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging 83 MAINTENANCE AND LUBRICATION Battery Battery Charging NOTE Always verify battery condition before and 1 2 hours after the end of charging Voltage Charge Time Using constant current charger 2 standard amps specified on top of battery 10096 12 8 13 0 volts None check at None required 3 mos from date of manufacture 5096 7596 12 0 12 5 volts Needs charge 5 11 hours 2596 5096 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 096 2596 11 5 volts orless Needs charge with At least 20 hours desulfating charger 75 100 12 5 12 8 volts May need slight 3 6 hours charge if no charge given check in 3 mon
55. haust 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 to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas 35 FEATURES AND CONTROLS Electrical Switches 1 Light Switch Hi Lo Beam Control The lights won t turn on unless the main key switch is on 2 Engine Stop Switch The engine will 2 not start or run when the switch is in the OFF position Its purpose is to provide the operator with a quick means of engine shutdown in case of an emergency To stop the engine press the lower end of the rocker switch down to the OFF position Before starting the engine press the upper end of the switch down to the ON position 3 Main Key Switch Turn the main key switch clockwise to the ON position __ before starting the engine Turn the main switch off to stop the engine and end all electrical power to the vehicle 3 4 Start Button To start the engine make sure the stop switch is in the ON position Turn the main key switch on Press the start button 36 FEATURES AND 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 sw
56. he 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 38 FEATURES AND CONTROLS Brakes Master Cylinder Check the brake fluid level in the master cylinder before each use of the ATV The master cylinder A is located on the right handlebar View the fluid level through the indicator window B on the top of the master cylinder This eye will appear dark when the fluid level is full When fluid is low the eye will be clear NOTE When checking the fluid level position the ATV on level ground with the handlebars turned so the top of the reservoir is level If the fluid level is low add DOT 3 brake fluid DO NOT OVERFILL See page 108 for the part numbers of Polaris products 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 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 an accident and severe injury or death 39 FEATURES AND CONTROLS Brakes 4 WARNING Applyin
57. he fuel valve off Be sure the fuel cap oil cap and seat are installed correctly and securely Always tie the frame of the ATV to the transporting unit securely using suitable straps or rope The rack bumper or handlebars do not offer enough support for tie down while transporting the unit Place the transmission in gear and lock the parking brake 99 SPECIFICATIONS Diy Weigh Ful Capacity Engine Oil Capacity Transmission Oi Rear Oi weight not to exceed 30 1bs 13 6 kg Tow Capacity Turn Radius Ground Clearance Length Widin Heig Seat Hough Wheel Bas 100 SPECIFICATIONS Rear Suspension Mono Shock Swing Arm w 6 5 in 16 5 cm travel Shock Adjustment Park Brake DC Plugs Read 101 SPECIFICATIONS Jetting Chart ALTITUDE AMBIENT TEMPERATURE Meters Feet Below 40 F 40 and above Below 5 C 5 and above we Change to a 40 pilot jet if operating the ATV at these higher elevations Clutching Chart Altitude Roller Weight Meters Feet Grams Each 0 1800 0 6000 6 14 5 grams 1800 3700 6000 12000 6 11 grams 102 POLARIS PRODUCTS Part No Description Engine Lubricant 2870791 Fogging Oil 12 oz Aerosol 2874865 Performance Synthetic 4 Stroke PS 4 OW 50 Oil qt 2874866 Performance Synthetic 4 Stroke PS 4 OW 50 Oil gal 2873602 2873603 2871653 2872276 2870465 2871322 2871423 2671460 2871515 2871551
58. hould 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 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 Snowmobiles All terrain vehicles ATVs 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 design and development of your Polaris vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your service needs during and after the warranty period We also take great pride in our complete line of apparel parts and accessories available through our online store at www purepolaris com Have your accessories and clothing deliver
59. ifications to achieve optimal performance Engine idle speed 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 clutch cover or engine case near the clutch box NOTE 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 Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 This vehicle complies with European directives 97 24 EC and 89 336 EEC 64 MAINTENANCE AND LUBRICATION 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 Record maintenance and service in the Maintenance Log beginning on page 111 NOTE Service and adjustments are important for proper vehicle operation If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following charts
60. il level Add the recommended oil as needed to maintain the oil level in the proper range See page 71 Drive slowly at first Select an open area that allows room to familiarize yourself with vehicle operation and handling Vary throttle positions Do not operate at sustained idle Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 47 Pull only light loads if equipped with a hitch During the break in period change both the oil and the filter at 20 hours 200 miles or one month whichever comes first See page 71 OPERATION Pre Ride Inspection 4 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 Ensure proper operation Brake fluid Foot brake Ensure proper level Ensure proper operation Front suspension Inspect lubricate if necessary Inspect lubricate if necessary Ensure free operation Rear suspension Steering oj AJo ors Tires Wheels fasteners nspect condition and pressure nspect ensure fastener tightness Frame nuts bolts fasteners Fuel and oil nspect ensure tightness Ensure proper levels Coolant level if applicable Ensure proper level Coolant hoses if applicable Inspect for leaks Throttle
61. ing the ATV for conditions in your area If the engine idle speed is not satisfactory and all other conditions are favorable the carburetor can be adjusted 1 Start the engine 2 Lock the parking brake 3 Allow the engine to run for approximately five minutes 4 Adjust the carburetor idle screw 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 90 MAINTENANCE AND LUBRICATION Adjustments Throttle Cable Freeplay The throttle cable adjuster is located at the right handlebar 1 Slide the boots A off the inline cable adjuster sleeve B Loosen the adjuster locknut C 2 Turn the adjuster until 1 16 to 1 8 freeplay is achieved at the thumb lever NOTE While adjusting freeplay be sure to flip the throttle lever back and forth several times 3 Tighten the locknut and slide the boots over the cable adjuster until they touch at the midpoint of the adjuster Side Panel Removal 1 Remove the seat 2 Remove the six fasteners A securing the side panel to the vehicle 3 Pull the side panel away from the vehicle 91 MAINTENANCE AND LUBRICATION Adjustments 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
62. is fully charged Set the battery in the battery holder Connect and tighten the red positive cable first Connect and tighten the black negative cable last Attach the hold down strap Verify that cables are properly routed DEVON UN et Reinstall the seat 82 MAINTENANCE AND LUBRICATION Battery Battery Storage Whenever the vehicle is not used for a period of three months or more remove the battery from the vehicle ensure that it s fully charged and store it out of the sun in a cool dry place Check battery voltage each month during storage and recharge as needed to maintain a full charge NOTE Battery charge can be maintained by using a Polaris Battery Tender charger PN 2871076 or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point Battery Charging The following battery charging instructions apply only to the installation of a sealed battery Read all instructions before proceeding with the installation of this battery The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Never pry the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealin
63. itch while the throttle is open 5 Override Switch Reverse Speed Limiter This vehicle is equipped with a reverse speed limiter system To gain additional power while backing depress the override switch Indicator Lights Your ATV has neutral and reverse indicator lights N Neutral Green R Reverse Amber 37 FEATURES AND CONTROLS Throttle Lever Press the throttle lever 1 toward the handlebar to increase engine speed and vehicle movement Engine speed returns to idle when 4 the lever is released ws This ATV is equipped with Polaris Electronic Throttle Control ETC which is designed to reduce the risk of a frozen or stuck throttle If the throttle cable should stick in an open position when the operator releases the throttle lever the engine will stop and power to the rear wheels will cease 4 amp 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 4 WARNING The Electronic Throttle Control ETC stops t
64. ls or military per sonnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Recalls How to Get Service In the Country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer If you move or are traveling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to per form the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of the destination country before you move Vehicles importation rules vary considerably from country to country You may be required to present docu mentation of your move to Polaris Industries in order to continue your warranty cover age You may also be required to obtain documentation from Polaris Industries in order to register your vehicle in your new country How to Get Service If
65. nd air filter Clean the air box and drain the sediment tube 97 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips See page 103 for the part numbers of Polaris products Fluid Levels Inspect fluid levels and change fluids if necessary Transmission Brake Fluid Engine Fogging Use Polaris Engine Fogging Oil Follow label directions carefully CAUTION Starting the engine during the storage period will disturb the protective oil film which can lead to engine damage Never start the engine during the storage period Lubricate Inspect all cables and lubricate with Polaris Cable Lubricant Follow lubrication guidelines in the maintenance section of the service or owner s manual to completely grease and lubricate the entire vehicle with Polaris Premium Season Grease Storage Area Covers 1 Make sure tire pressure is at specification 2 Using suitable supports under the frame raise the vehicle slightly so that the tires are not touching the ground 3 Be sure the storage area is well ventilated 4 Cover the machine with an appropriate cover Do not use plastic or coated materials as they do not allow proper ventilation to prevent condensation corrosion and oxidation 98 MAINTENANCE AND LUBRICATION Cleaning and Storage Transporting an ATV Follow these procedures when transporting an ATV 1 Turn off the engine and remove the key to prevent loss during transporting Turn t
66. nents designed for use on this ATV and should be installed and used according to approved instructions See your authorized Polaris ATV dealer for more information SAFETY Operator Safety 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 pages 52 53 28 SAFETY Operator Safety 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 4 WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death Always remove the ignition key when the vehicle is not in use 4 WARNING After any overturn or accident have a qualified service dealer inspect the entire vehicle for po
67. ng on page 65 Maintain the oil level at the bottom of the check plug hole We recommend the use of Polaris Premium ATV Angle Drive Fluid Refer to the gearcase specifications chart on page 74 See page 103 for the part numbers of Polaris products Oil Check 1 Position the vehicle on a level surface 2 Remove the check plug A and view the oil level 3 Remove the fill plug B Add the recommended oil as needed 4 Reinstall the fill plug Torque to specification 5 Reinstall the check plug Torque to specification 6 Check for leaks Oil Change 1 Remove the skid plate 2 Remove the drain plug Drain the oil into an appropriate container Discard used oil properly 3 Clean and reinstall the drain plug with a new sealing washer Torque to specification Remove the fill plug and add the recommended gearcase oil Reinstall the fill plug Torque to specification Check for leaks Reinstall the skid plate DX 75 MAINTENANCE AND LUBRICATION Lights 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 Do not service the headlamps until they ve cooled sufficiently Headlight Lamp Replacement To access the assembly from the front remove the front cover and unplug the wiring harness Remove the headlight
68. o resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate personnel 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 recom mend the use of Polaris engine oil 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty SPARK ARRESTOR Polaris warrants that the spark arrestor in this vehicle will meet the efficiency requirements of 43 CFR 8340 1 c for at least 1000 hours when subjected to normal use and when mainte nance and installation are in accordance with Polaris recommendations 108 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WAR RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCA TION This policy does not apply to vehicles that have received authorization for export from Polaris Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warranty or service bulletin coverage if you have any questions This policy does not apply to vehicles registered to government officia
69. or wear damage and looseness 5 Check the security and surface condition of the disc NOTE Change the brake pads when they re worn to 3 64 1 cm 3 64 1 cm 85 MAINTENANCE AND LUBRICATION Adjustments Brakes Rear Periodically measure the freeplay of the rear brakes To adjust rear brake freeplay turn the adjuster nuts A at the rear brake drum 40 80 10 20 mm Brake Lever Travel Rear Service the brakes when brake lever travel reaches 2 1 2 65 mm Always service the brakes when there is no longer sufficient stopping ability at the specified lever travel setting 86 MAINTENANCE AND LUBRICATION Adjustments 4 WARNING Severe injury or death can result from improper toe alignment and adjustment Do not attempt to adjust tie rod alignment All tie rod adjustments should be performed by an authorized Polaris dealer Toe Alignment Use the following procedure to check the toe alignment of the vehicle The recommended toe alignment is 1 8 1 4 3 6 mm toe out 1 Setthe handlebars in a straight ahead position 03 al 200 ab Bad Face 200 O46 NOTE The steering frog can be used as an indicator of whether the handlebars are straight The frog should always point straight back from the steering post 2 Place stands A in front of the vehicle perpendicular to the rear tires See illustration 3 Tie an el
70. ox B and tighten the clamp Do not over tighten the clamp as filter damage C could occur 95 MAINTENANCE AND LUBRICATION Cleaning and Storage See page 103 for the part numbers of Polaris products Cleaning the ATV Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components With a few precautions your ATV can be cleaned much like an automobile Washing the ATV The best and safest way to clean your ATV is with a garden hose and a pail of mild soap and water Use a professional type washing mitten cleaning the upper body first and the lower parts last Rinse with water frequently and dry with a chamois to prevent water spots NOTE f warning and safety labels are damaged contact your 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 Your ATV can be waxed with any non abrasive automotive paste wax Avoid the use of harsh cleaners since they can scratch the body finish CAUTION Certain products including insect repellants and chemical
71. r tipover which could result in serious injury or death Use caution when applying the rear brake Do not aggressively apply the rear brake when going forward The rear wheels may skid and slide sideways causing loss of control and serious injury or death 41 FEATURES AND CONTROLS Parking Brake 4 WARNING Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death Always check to be sure the parking brake is disengaged before operating Setting the Parking Brake 1 2 Squeeze the left brake lever 1 Push the park brake lock 2 down This will prevent the lever from returning to the released position To release the parking brake lock squeeze and release the brake lever The parking brake will release automatically Important Safeguards The parking brake may relax if left on for a long period of time AI ways block the wheels to prevent rolling Never depend on the parking brake alone if the ATV is parked on a hill Always block the wheels to prevent rolling 42 FEATURES AND CONTROLS Choke The choke assists in starting a cold engine See page 48 for correct choke and throttle settings during starting Fuel Filter The in line fuel filter should be replaced by your dealer after every 100 hours of operation or annually Do not attempt to clean the fuel filter Fuel Tank The fuel tank filler cap A is located directly b
72. recommendations for ambient temperature operation CAUTION Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands 70 MAINTENANCE AND LUBRICATION Engine Oil Check Maintain the oil level at the center of the sight glass Do not overfill 1 Position the vehicle on a level surface 2 View the oil level through the sight glass A on the right side of the vehicle 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 rises to the top of the sight glass change the oil immediately 3 Remove the fill plug B and add the recommended oil as needed 4 Reinstall the fill plug 71 MAINTENANCE AND LUBRICATION Oil and Filter Change CAUTION If the ATV is left without oil in the system for extended periods the oil pump may lose its prime which could result in engine damage Always replace the oil and filter within a few hours of draining the oil Do not allow the vehicle to be without oil overnight Obtain the correct oil filter and an adequate supply of oil so the oil and filter change can be completed without interruption Position the vehicle on a level surface Clean the area around the drain plug on the bottom of the engine crankcase Run the engine for two to three minutes until warm Stop the engine 4 CAUT
73. refore we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury The warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power NOTE The addition of certain accessories including but not limited to mowers blades tires sprayers or large racks may change the handling characteristics of the vehicle Use only Polaris approved accessories and familiarize yourself with their function and effect on the vehicle 11 SAFETY Operator Safety 4 WARNING 12 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 ATV RiderCourse offered by Polaris through the SVIA They should then regularly practice the skills learned in the course and the operating techniques described in the Owner s Manual For more information about the ATV RiderCourse contact ATV Enrollm
74. rturn and result in serious injury or death Avoid climbing steep hills 25 maximum Use extreme caution when operating on hills and follow proper operating procedures outlined in the owner s manual If the vehicle stalls while climbing a hill never back down the hill Use the K turn to turn around 58 OPERATION Driving Safely K Turn Turning Around on a Hill 1 in Beets D 10 11 Squeeze the front right brake lever to stop the vehicle Keep your weight uphill Lock the parking brake Leave the transmission in forward gear and shut off the engine Dismount on the uphill side of the vehicle or on either side if the vehicle is pointing straight uphill Staying uphill of the vehicle turn the handlebars full left While holding the brake lever release the parking brake lock and slowly allow the vehicle to roll around to your right until it s pointing across the hill or slightly downward Squeeze and hold the left brake lever Remount the vehicle from the uphill side Keep your weight uphill With the transmission still in forward start the engine Release the brake and drive slowly downhill Control speed with the rear brake until the vehicle is on level ground 59 OPERATION Driving Safely Driving Through Water Follow these procedures when operating through water 1 Check water depths and current before crossing 2 Avoid operating in water deeper than the bottom of the footres
75. s will damage plastic surfaces Use caution when using these products near plastic surfaces 96 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips See page 103 for the part numbers of Polaris products CAUTION Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur Never start the engine during the storage period Exterior Make necessary repairs and then clean the ATV thoroughly with mild soap and warm water to remove all dirt and grime Don t use harsh detergents or high pressure washers Some detergents deteriorate rubber parts Use dish soap type cleaners only High pressure washers may force water past seals Fuel Stabilizer Polaris Carbon Clean is a fuel stabilizer and fuel system dryer It cleans the fuel system the combustion chamber and the exhaust ports It also prevents bacterial growth and promotes better starting after the storage period 1 Fill the fuel tank with fuel and add Polaris Carbon Clean or Fuel Stabilizer Follow the instructions on the container for the recommended amounts 2 Start the engine and allow it to run for 15 20 minutes so the stabilizer can disperse through the fuel in the tank and carburetor 3 Stop the engine 4 Tum the fuel valve off 5 Drain the carburetor bowl Oil and Filter Warm the engine and change the oil and filter Air Filter Air Box Inspect and clean or replace the pre cleaner a
76. s as described in the owner s manual Always check the terrain 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 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 traveling downhill See page 56 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 Never travel backwards down a hill 21 SAFETY Operator Safety 4 WARNING 22 POTENTIAL HAZARD Improperly crossing hills and turning on hills WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of control or overturn HOW TO AVOID THE HAZARD Nev
77. ssible damage including but not limited to brakes throttle and steering systems 4 WARNING Safe operation of this rider active vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control which could result in severe injury or death CAUTION Always keep combustible materials away from the exhaust System Exposure to the hot components could result in a fire 29 SAFETY Safety Decals and Locations Warning decals have been placed on the ATV for your protection Read and follow the instructions of the decals and other warnings on the carefully If any of the decals shown in this manual differ from the decals on your ATV always read and follow the instructions of the decals on the ATV If any decal becomes illegible or comes off contact your Polaris dealer to purchase a replacement Replacement safety decals are provided by Polaris at no charge The part number is printed on the decal Never operate this ATV on HILLS steeper than 25 degrees 6 To prevent flipover on hilly terrain when going up or down use throttie and brakes gradually REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent flipover avoid sudden braking or sharp turns PARKING BRAKE may relax when used for more than 5 minutes When parking on grades leave shift
78. ths 84 MAINTENANCE AND LUBRICATION Adjustments Brakes Front The front brakes are hydraulic disc brakes These brakes are self adjusting The following checks are recommended to keep the hydraulic 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 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 1 Always keep brake fluid at an adequate level see page 39 NOTE Under normal operation the diaphragm extends into the reservoir as fluid level drops If the fluid level is low and the diaphragm is not extended a leak is likely and the diaphragm should be replaced Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper operation Use Polaris DOT brake fluid Do not overfill 2 Check the brake system for fluid leaks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads f
79. ts A If it s unavoidable travel slowly balance your weight carefully and avoid sudden movements Maintain a slow and steady forward motion Do not make sudden turns stops or throttle changes 3 Choose a crossing where both banks have gradual inclines Drive slowly Avoid rocks and obstacles 5 Wet brakes may have reduced stopping ability Always test your brakes after leaving water If necessary apply them lightly several times to allow friction to dry out the pads After running the vehicle in water it s critical to have it serviced as outlined in the maintenance chart See page 65 The following areas need special attention engine oil transmission oil rear gearcase and all grease fittings 4 CAUTION Major engine damage can result if the vehicle is not thoroughly inspected after operation in water Perform the services outlined in the maintenance chart If your vehicle becomes immersed or is operated in water that exceeds the footrest level take it to your dealer for service before starting the engine If your vehicle becomes immersed and it s impossible to take it to a dealer before starting it follow the steps described on page 79 Have the vehicle serviced by your dealer at the first opportunity 60 OPERATION Driving Safely Driving Over Obstacles Always check for obstacles before operating in a new area Be alert Watch the terrain Use extra caution Never operate over large obstacles
80. ttery voltage Clogged air filter Reverse speed limiter malfunction Electronic throttle control malfunction Other mechanical failure Overheated engine Clean radiator screen and core if equipped Clean engine exterior See your Polaris dealer 106 WARRANTY LIMITED WARRANTY Polaris Sales Inc 2100 Highway 55 Medina MN 55340 givesa SIX MONTH LIMITED WARRANTY on all components of the Polaris Terrain Vehicle against defects in material or workmanship Polaris also gives a one year limited warranty on the final drive chain for failure due to defects This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transferrable to another consumer during the war ranty period through a Polaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty 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 s
81. ty covers components whose failure would increase an en gine s emissions including electronic controls fuel injection exhaust gas recirculation aftertreatment or any other system utilized in this vehicle to control emissions Replac ing or repairing other components not covered by this emissions warranty or the standard warranty is the responsibility of the owner including the parts labor and other costs associated with recommended maintenance The exclusive remedy for breach of this limited warranty shall be at the exclusive option of Polaris repair or replacement of any defective materials components or products THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS 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 CON TRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IM PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICU LAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS 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 if it is inconsistent with the controlling state law This limited warranty excludes failures not ca
82. used by a defect in material or workman ship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or any engine that has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of Polaris If you have any questions regarding your warranty rights and responsibilities you should contact the Polaris Warranty Department at 1 763 417 8650 110 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 111 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 112 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 113 INDEX A Adjustments 85 95 Age Restrictions 6 Air Filter esses reme mx te 95 B Battery rele RAS 82 84 Battery Charging 83 84 Battery Installation 82 Battery Removal 82 Battery Storage 83 Brake 41 Brake Lever Left 40 Brake Lever Right 40 Brake Lever Travel 86 Brakes etre emen 39 41 Brakes Front 85 Brakes Rear 86
83. ve 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 plug or incorrect carburetion adjustments 2 Wet Fouled The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended injection oil improper use of the choke or incorrect carburetion adjustments Spark Plug Removal and Replacement 1 Remove the spark plug cap A 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 A Torque to 14 ft Ibs 19 Nm 78 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 BR 8 9 10 11 Move the ATV to dry land or at the very

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