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Polaris Predator User's Manual

1. 0 eee eee eee ees 52 OPERATION La ote es ett tt lis bi Oi Re seh ie esas des idit Dos 69 EMISSION CONTROL SYSTEMS 0 c eee eee eee 89 MAINTENANCE AND LUBRICATION sssese I 91 ADJUSTMENTS scx x be i aeren e Pw CE eR Ea ed Eo bare 142 CLEANING AND STORAGE pordi creet ateue aE AA eee 160 TROUBLESHOOTING i docu nteni ates aA da P T ua anta onera 167 POLARIS PRODUCTS 4225 ei VE ORE NERIS A A eee 175 SPEGIFIGATIONS 4h veux eE A E E Aa ds 176 WARRANTY S retos cece tk tes cabo ie A E O a oct dades 178 INDEX carpea aaa EE wel te Ge Reads ceed ae OR LP n EU TEL den 185 VEHICLE IDENTIFICATION NUMBERS The frame vehicle identification number VIN 1 and engine serial number 2 are important for model identification when registering your vehicle when obtaining insurance and when ordering replacement parts In the event your vehicle is stolen these numbers are essential to the recovery and identification of your vehicle Remove the spare key and store it in a safe place Your key can be duplicated only by mating a Polaris key blank with one of your existing keys If both keys are lost the ignition switch must be replaced See your Polaris dealer NOTE Record your vehicle s ID numbers and key number 3 in the spaces provided VEHICLE IDENTIFICATION NUMBERS Frame VIN Vehicle Model Number Engine Serial Number Key Number SAFETY Safety Decals and Locations Warning decals have been placed o
2. 89 90 0 Oil Change 107 111 Oil Filter Change 107 111 Oll Level oj seve ds 105 106 OPERATION ics Gaede deu 69 88 Operator Restrictions 14 Operator Safety 14 51 P Parking Brake 61 62 Parking on an Incline 85 Periodic Maintenance Schedule 91 100 POLARIS PRODUCTS 175 Pre Ride Inspection 72 73 186 R Rear Suspension 152 154 Rebound Damping 153 S Safe Riding Gear 12 13 SAFETY S ob eese PERS RIS 8 51 Safety Decals and Locations 8 11 Safety Training 15 Setting the Parking Brake 61 Shift Pedal lt asias ees e hie n 65 SINEAD s Gime ele Rese eA SO Giese 67 Side Panel Removal 123 Spark Arrestor 90 130 131 Spark Plug Removal and Replacement 127 129 Spark Plugs 125 129 SPECIFICATIONS 176 177 Spring Preload 151 152 Starting a Cold Engine 74 75 Starting a Warm Engine 76 Steering Assembly 149 Storage Recommendations 162 165 Suspension Adjustments 150 154 Suspension Settings 149 T TABLE OF CONTENTS 5 Taillight Brakelight Lamp Replacement 121 Throttle Cable Freeplay 156 Throttle Lever osa es tex iiss 56 Tie crus EVELCEYST 138 139 Toe Alignment 144 145 Transporting the A
3. Personal watercraft RANGER utility vehicles Victory motorcycles Polaris Professional Series Workmobiles Utility Task Vehicles UTVs e Personal Task Vehicles PTVs e All Surface Loaders ASLs WELCOME We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today Many years of experience have gone into the engineering design and development of your Polaris vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your service needs during and after the warranty period We also take great pride in our Parts Apparel and Accessories PAA products available through our online store at www purepolaris com Have your accessories and clothing delivered right to your door TABLE OF CONTENTS WELCOME 2 es eat heat et ial ad melds RUM RE teen ta pude Saree 3 VEHICLE IDENTIFICATION NUMBERS 00 eee eee eee 6 SAFETY ania Cr 8 FEATURES AND CONTROLS
4. Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 72 During the break in period change both the oil and the filter after one hour of operation or after using the first tank of fuel 71 OPERATION Pre Ride Inspection AWARNING 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 Use the following checklist to verify that your vehicle is in proper working condition before each use Item Inspection Procedure 1 Fuel tank and engine oil level Fill both to their proper levels See page 105 2 Engine coolant Check for proper level at the recovery bottle See page 115 3 All brakes Check operation adjustment and fluid levels includes foot brake See page 143 4 Clutch Lever Check for proper operation and correct adjustment See page 155 72 OPERATION Pre Ride Inspection 13 14 Throttle Check for free operation and closing See page 156 Steering Check for free operation noting any unusual looseness in any area Headlight Taillight Brakelight Check operation of all indicator lights and switches Engine stop switch Check for proper function Air cleaner element Check for dirt clean or replace Tires Check condition and pressures Wheels Check for tightness of wheel nuts and axle nuts Check
5. 20 minutes of operation for the stabilizer to disperse through the fuel in the tank and carburetor Turn the fuel valve off and drain the carburetor bowl NOTE Carbon clean will also reduce the possibility of bacterial growth in the fuel system 162 CLEANING AND STORAGE Storage Recommendations Oil and Filter Warm the engine and change the oil and filter See page 107 Air Filter Air Box Inspect and clean or replace the pre cleaner and air filter Clean the air box and drain the sediment tube Breather Filter Inspect and clean or replace the breather filter inside the airbox Fluid Levels Inspect all fluid levels and change as outlined in the Maintenance Schedule beginning on page 91 Battery Refer to pages 135 136 for battery storage and battery charging procedures 163 CLEANING AND STORAGE See page 175 for the part numbers of Polaris products Storage Recommendations Fog the Engine 1 Start the engine and allow it to warm up Turn engine off 2 Unlatch and remove the seat 3 Loosen the intake duct clamp at the carburetor and pull the duct off the carburetor 4 Start the engine and spray Polaris fogging oil or a comparable product into the carburetor following the instructions on the fogging oil container 5 Turn the engine off reassemble the intake duct to the carburetor secure the clamp and reinstall the seat 164 CLEANING AND STORAGE Storage Recommendations Inspect and Lubricate Inspect all c
6. Low battery voltage Old poor or non recommended fuel 172 Solution TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Clogged dirty or wet air filter Inspect and clean or replace Electronic throttle control ETC malfunction See your Polaris dealer Other mechanical failure See your Polaris dealer Overheated engine Clean radiator screen and core if equipped Clean engine exterior See your Polaris dealer Engine Overheating Possible Cause Solution Debris lodged in screen Remove and clean the screen Plugged radiator Use a garden hose to flush any debris from the radiator fins NOTE High pressure washers can deform the radiator fins and reduce cooling efficiency 173 174 NOTES POLARIS PRODUCTS Part Description Engine Lubricant 2874414 Performance Synthetic 4 Stroke PS 4 Oil qt 2874415 PS 4 Oil gal i Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz Additives Miscellaneous E Part Description Coolant 0 40 Coolant gal 0 40 Coolant qt N 871323 871534 o N o N 871326 Carbon Clean Plus 12 oz 870652 870990 872893 2871322 2871423 2871460 287132 287207 287234 i Fuel Stabilizer 16 oz OT3 Brake Fluid 12 oz ngine Degreaser 12 oz N Jg N m 175 SPECIFICATIONS Predator 500 e 8 Demessm eno 00 176
7. PSI KPa FRONT 4 27 6 REAR 4 27 6 MAXIMUM WEIGHT CAPACITY Gross Vehicle Weight Location G INCLUDING MACHINE DRIVER AND CARGO IS 645 LBS 293 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 For stability on rough or hilly terrain reduce speed and cargo Read Owner s Manual for more detailed loading information 7171022 Location D CE Location H SAFETY ATTENTION Operation of this vehicle without the air filter element will severely damage the engine Clean pre filter element often more frequent cleaning required in dusty Specific carburetor jetting and adjustments are required depending on temperature and altitude See your Owner s Manual Factory setting 40 to 80 F at 0 3000 feet 5 to 27 C at 0 900 meters 7079902 Location under seat 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 NEST PAS DESTINE A ETRE UTILISE SUR LES CHEMINS PUBLICS 7170983 11 SAFETY Safe Riding Gear Always wear clothing suited to the type of riding ATV riding requires special protective clothing for comfort and to reduce the chance of injury 1 Helmet Your helmet is the most important piece of protective gear for safe riding A helmet can prevent a severe hea
8. 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 proce dure set out above your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind Vehicles registered to Government officials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions call Polaris Customer Assistance United States 1 763 417 8650 Canada 1 204 925 7100 184 A ADJUSTMENTS 142 159 Air Filter Systems 112 113 B Battery so eet rue Res 134 Battery Charging 136 137 Battery Installation 135 Battery Removal 134 Battery Storage 135 Brake Fluid 60 Brake Levers ye i e ese hut her 59 BrakeS oen opsesrue e euh 142 143 Break In Period 70 71 C Cab Removal Front 124 Cab Removal Rear 123 Camber and Caster 149 Carburetor Idle RPM 158 159 Chain Tension 146 148 Chokes ovo S WR SEES 64 CLEANING AND STORAGE 160 166 Clutch Lever rn pannaan UAR 57 Clutch Lever Freeplay 155 Compression Damping 154 C Co
9. Release the eight airbox cover clips 3 and remove the cover 4 5 Remove the air filter 5 Inspect and replace if necessary 6 Remove the pre filter 6 and breather filter 7 Wash both in soapy water then rinse let dry and reinstall 112 MAINTENANCE AND LUBRICATION Air Filter Systems 7 Reinstall the air filter 8 Reinstall the airbox cover and secure the clips 9 Reinstall the intake duct to the carburetor and secure the clamp 10 Check the hoses for cracks deterioration abrasion or leaks Replace as needed CAUTION Operation of your vehicle without a breather filter can cause engine damage Always reinstall the breather filter after removing for service 113 MAINTENANCE AND LUBRICATION Engine Cooling System The engine coolant level is controlled or maintained by the recovery system The recovery system components are the recovery bottle radiator filler neck radiator pressure cap and connecting hose To ensure that the coolant maintains its ability to protect the engine we recommend that you completely drain the cooling system every two years and add a fresh mixture of antifreeze and water Polaris recommends the use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water See page 175 for the part numbers of Polaris products NOTE Polaris Premium 60 40 is already premixed and ready to use Do not dilute with wa
10. SPECIFICATIONS Predator 500 Driving System Type Rear Two Wheel Drive Tire Size Pressure Front 21x 7 10 4 psi Jetting Chart Altitude AMBIENT Below 40 F 40 F and above 5 C and above TEMPERATURE Below 5 C Meters 0 1800 Feet 0 6000 1800 3700 147 5 6000 12000 177 WARRANTY LIMITED WARRANTY Polaris Sales Inc 2100 Highway 55 Medina MN 55340 gives a SIX MONTH LIMITED WARRANTY on all com ponents of the Polaris All Terrain Vehicle ATV against defects in material or workmanship Polaris also gives a one year limited warranty on the final drive chain for failure due to defects This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transferrable to another consumer during the warranty period through a Polaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty THE PURCHASER MUST COMPLETE AN ATV SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE ATV No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement If you have not signed the original registration and received the c
11. Turn the adjusting ring to the left A to increase preload Turn the ring to the right B to decrease preload NOTE See Suspension Settings on page 149 ADJUSTMENTS 151 ADJUSTMENTS Rear Suspension The rear suspension spring preload shock rebound damping and shock compression damping may be adjusted to suit different riding conditions and operator weight Spring Preload 1 Raise and safely support the rear of the ATV off the ground to allow the suspension to fully extend 2 Loosen the jam nut 1 and back it away from the adjusting ring 3 Turn the adjusting ring 2 to the left A to increase preload Turn the ring to the right B to decrease preload See Suspension Settings on page 149 4 Tighten the jam nut firmly against the adjuster ring 152 Rear Suspension Rebound Damping 1 Locate the rebound damping clicker drum between the lower spring seat and the lower shock mount Turn the clicker to the left A to decrease the rebound damping Turn it to the right B to increase rebound damping NOTE The rebound damping is factory set at 10 clicks from fully closed See Suspension Settings on page 149 ADJUSTMENTS 153 ADJUSTMENTS Rear Suspension Compression Damping The compression damping clicker drum is located on top of the shock reservoir under the left rear fender It has eight possible positions ranging from position 1 softest to 8 firmest The compression damping is
12. breather hose and 50 hrs 6 months Inspect filter in airbox 98 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule rem Houses Frequency Remarks Coolant strength 50 hrs 6 months Inspect strength seasonally pressure test system annually La Coolant system pressure 100 hrs Annually Pressure test system annually test Spark plug 100 hrs Annually Inspect replace as needed Ignition Timing NA Annually Inspect adjust as needed Fuel system 100 hrs Annually Check for leaks at tank cap lines fuel valve pump and carburetor replace lines every two years More often under severe use such as dirty or wet conditions Emission Control System Service California Wi Dealer service item Polaris Premium All Season Grease 99 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule em Houses Frequency Remarks Radiator 100 hrs Annually Inspect clean external surface change coolant every 2 years m cooing system hoses 00h Anmualy Eronemoms 100ms Annualy W Brake fluid 200 hrs Change every two years Spark arrestor sons Front wheel bearings 300 hrs Inspect replace as needed Toe adjustment As required Periodic inspection adjust when parts are replaced resaignraim amp sreaired Adiustas needed p More often under severe use such a
13. could result in component failure and lead to serious injury or death Have a Polaris dealer perform these services phem HewsMH es Frequency Remarks A Arm A 50 hrs 3 months Inspect tighten fasteners grease also after washing ATV or driving in water Rear axle 25 hrs 3 months Inspect grease also after washing ATV Rear eccentric B or driving in water Swing arm pivot 25 hrs 3 months Disassemble components clean and grease Upper steering post C 50 hrs 6 months Inspect tighten fasteners grease after washing ATV or driving in water More often under severe use such as dirty or wet conditions Emission Control System Service California Wi Dealer service item Polaris Premium All Season Grease 96 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Lubrication Points 97 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule AWARNING Improperly performing the procedures marked with a m could result in component failure and lead to serious injury or death Have a Polaris dealer perform these services ten Houses Frequency Remarks E Carburetor float bowl Drain bowl periodically and prior to stor age i Throttle Cable ETC Switch Inspect adjust replace if necessary Choke enricher cable Inspect adjust lubricate replace if neces sary be ili chain s 50 hrs 6 months Inspect daily adjust and lubricate if needed il i
14. defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law 179 WARRANTY WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WAR RANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied war ranty lasts so the above limitation may not apply to you if inconsistent with controlling state law 180 WARRANTY HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service you must take it to a Polaris dealer authorized to repair Polaris ATVs When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR R
15. factory set at position 4 To adjust turn the clicker drum to the desired setting See Suspension Settings on page 149 154 ADJUSTMENTS Clutch Lever Freeplay 1 Measure clutch lever freeplay between the perch and the lever A This distance should be 1 8 3 16 3 1 mm 4 7 mm If adjustment is required slide the clutch perch pivot boot down the clutch cable to access the clutch adjustment screw B and lock ring C Loosen the lock ring and turn the screw in clockwise to increase lever travel Turn the screw out counterclockwise to decrease lever travel Tighten the lock ring Squeeze the lever fully and release Slightly squeeze the lever again until a slight resistance is felt Measure the freeplay again If necessary repeat the adjustment procedure until proper freeplay is attained Replace the clutch perch pivot boot over the screw and lock ring 155 ADJUSTMENTS Throttle Cable Freeplay AWARNING Improper adjustment of throttle cable freeplay can result in loss of control which could result in serious injury or death Polaris recommends that this procedure be performed by a Polaris dealer to ensure that it s done correctly Mechanically knowledgeable persons who perform this procedure must follow the adjustment procedures exactly Throttle cable freeplay is adjusted at the handlebar 1 Slide the boots 1 off the inline cable 1 2 3 1 adjuster sleeve 2 and loosen the adj
16. friction dry out the pads SAFETY Operator Safety A 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 in the owner s manual Always maintain proper tire pressure as described in the owner s manual and on safety decals 47 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Operating the ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of the ATV may cause changes in handling which could lead to an accident HOW TO AVOID THE HAZARD Never modify the ATV through improper installation or use of accessories All parts and accessories added to the vehicle must be genuine Polaris Industries Inc or equivalent components designed for use on this ATV and should be installed and used according to approved instructions See your authorized Polaris ATV dealer for more information 48 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Overloading the ATV or carrying towing cargo WHAT CAN HAPPEN Overloading or carrying towing cargo can cause changes in vehicle handling which could lead to loss of control or an accident HOW TO AVOID THE HAZARD Never haul cargo or tow a load
17. 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 27 SAFETY Operator Safety 28 A WARNING POTENTIAL HAZARD Operating an ATV on paved surfaces including sidewalks paths parking lots and driveways WHAT CAN HAPPEN ATV tires are designed for off road use Operating on paved surfaces may adversely affect the handling of the ATV and could result in loss of control accident and or injury HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement If it s unavoidable travel slowly and avoid sudden turns or stops SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Operating this ATV on 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 29 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet eye protection and protective clothing WHAT CAN HAPPEN Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident Operating without eye protection could result in an accident and could increase the cha
18. start or run when the switch is in the OFF position 3 Main Key Switch To start the engine the main key switch must be in the RUN position OFF RUN OFF jzu 2 NOTE Both the main switch and the emergency engine stop switch will shut off all electrical power to the vehicle including lights To stop the engine quickly slide the stop switch either right or left to the OFF position 53 FEATURES AND CONTROLS Lights 1 Headlight HI LO Switch 2 Neutral Indicator Lamp 3 High Temp Indicator Lamp 54 FEATURES AND CONTROLS Light Switches The light switch is located on the left handlebar It s used to turn the lights on and off and to switch the lights from HI to LO NOTE The lights won t work unless the key is in the ON position and the engine stop switch is in the RUN position AWARNING 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 55 FEATURES AND CONTROLS AWARNING 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 yo
19. sure the parking brake is disengaged before operating Setting the Parking Brake 1 Place the transmission in first gear or neutral 2 Squeeze and release the brake lever 1 two or three times then squeeze and hold 3 Push the park brake lock 2 forward to engage the lock Release the brake lever 4 To release the parking brake lock squeeze and release the brake lever It will return to its unlocked position 61 FEATURES AND CONTROLS Parking Brake Important Safeguards The parking brake may relax if left on for a long period of time Always block the wheels to prevent rolling Always block the wheels on the downhill side of the ATV if leaving it parked on a hill Another option is to park the ATV in a sidehill position Never depend on the parking brake alone if the ATV is parked on a hill Always block the wheels to prevent rolling Place the transmission in first gear or neutral before locking the park brake 62 FEATURES AND CONTROLS Fuel Valve The fuel valve 1 is located under the fuel tank on the left d NN side of the ATV It has three positions M OFF For vehicle storage and when transporting ON For normal operation RES For reserve supply if main supply is exhausted NOTE There s about a 5 to 8 mile 8 to 13 km range on reserve gas Always refill the gas tank as soon as possible after using the main supply Always return the valve to the ON position after refueling 63
20. surface of the rear tires on each side of the vehicle and goes around the stands in front of the vehicle 4 Measure the distance from the string to the rim at the front and rear of the front rim 3 The difference between these two measurements should be between 0 and 1 16 toe out NOTE If you discover improper alignment see your Polaris dealer for service ADJUSTMENTS Chain Tension CAUTION Never adjust or operate the vehicle with the rear drive chain too loose or too tight Severe damage to the transmission and drive components can result Chain tension must be inspected with the swing arm in the position shown in the illustration so that the axle swing arm pivot and drive sprocket are aligned horizontally B 146 ADJUSTMENTS Chain Tension Check the amount of chain slack by moving the vehicle slightly forward to remove slack at the top side of the chain NOTE The chain has a press on master link A chain tool must be used if it s necessary to remove the chain for service 1 Collapse the suspension with an adjustable buckle type trailer tie down strap A Fasten the strap around the axle and rear bumper tube 2 Tighten the strap until a straight line B can be drawn from the axle to the transmission output shaft intersecting the swing arm pivot This establishes the tightest chain position 3 At this point C the chain should have 1 4 3 8 6 9 cm deflection Use the procedure on the followi
21. to 12 8 VDC Check all connections and tighten 167 TROUBLESHOOTING Engine Turns Over Fails to Start Possible Cause Solution No spark to spark plug Inspect plug s verify stop switch is on 168 TROUBLESHOOTING Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Backfires Possible Cause Solution Weak fouled or defective spark plug Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs 169 TROUBLESHOOTING Engine Runs Irregularly Stalls or Misfires Possible Cause Solution Fouled or defective spark plug Worn or defective spark plug wire Incorrect spark plug gap or heat range Loose ignition connections Kinked or plugged fuel tank vent line Old poor or non recommended fuel Electronic throttle control ETC malfunction Other mechanical failure 170 TROUBLESHOOTING Engine Runs Irregularly Stalls or Misfires Possible Lean Fuel Mixture Cause Solution Possible Rich Fuel Mixture Cause Solution 171 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Water present in fuel Overuse of choke Fouled or defective spark plug Worn or defective spark plug wire Incorrect spark plug gap or heat range Loose ignition connections
22. towels Coat the terminals with dielectric grease or petroleum jelly AWARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing a battery always disconnect the negative black cable first When reinstalling the battery always connect the negative cable last Battery Removal 1 Remove the rear cab see page 123 and disconnect the strap securing the battery in position 2 Disconnect the black negative cable first then disconnect the red positive cable 3 Lift the battery out of the ATV 134 MAINTENANCE AND LUBRICATION Battery Installation 1 Set the battery in the battery holder 2 Connect and tighten the red positive cable first then connect and tighten the black negative cable 3 Attach the hold down strap and reinstall the rear cab 4 Verify that cables are properly routed NOTE When installing a new battery make sure it s fully charged prior to its initial use Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance Battery Storage When the vehicle is placed in storage for three months or more the battery should be removed and stored out of the sun in a cool dry place Test and recharge the battery monthly and before reusing 135 MAINTENANCE AND LUBRICATION Battery Charging Sealed Battery The most important part of maintai
23. 0 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with At least 20 hours desulfating charger 137 MAINTENANCE AND LUBRICATION Tires 138 AWARNING Operating your ATV with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death Maintain proper tire pressure as described on the ATV decal and in the owner s manual Always use original equipment size and type when replacing tires Make sure the wheels are installed properly Always replace tires when the tread depth measures 1 8 3 cm or less MAINTENANCE AND LUBRICATION Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 cm or less See illustration Wheel Removal 1 2 3 1 8 3 cm Stop the engine place the transmission in gear and lock the parking brake Loosen the wheel nuts slightly Elevate the side of the vehicle by placing a suitable PAN stand under the frame Remove the wheel nuts and remove the wheel 139 MAINTENANCE AND LUBRICATION Wheel Installation 1 Place the transmission in gear and lock the parking brake 2 Place the wheel on the wheel hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation 3 Install the wheel nuts and finger tighten 4 Lower the ve
24. 00 638 2772 or call Polaris at 1 800 342 3764 22 SAFETY Operator Safety Equipment Modifications We are concerned for the safety of our customers and for the general public Therefore we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury The warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power NOTE The addition of certain accessories may change the handling characteristics of the vehicle Use only Polaris approved accessories and familiarize yourself with their function and effect on the vehicle 23 SAFETY Operator Safety 24 A WARNING POTENTIAL HAZARD Operating this ATV without proper instruction WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Polaris Operators should regularly practice the skills learned in the course and the operating techniques described in the ow
25. ESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate 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 recommend the use of Polaris engine oil 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty 181 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WARRANTY OR SERVICE BUL LETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCATION This policy does not apply to vehicles that have received authorization for export from Polaris Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warran ty or service bulletin coverage if you have any questions This policy does not apply to vehicles registered to government officials or military personnel on assignment out side the country of the selling dealer s authorized
26. FEATURES AND CONTROLS Fuel Tank The fuel tank filler cap is located directly below the handlebar Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Fuel Filter The fuel valve has an internal fuel filter Do not attempt to clean the fuel filter See your Polaris dealer for service if you suspect the fuel filter is plugged Choke The choke assists in starting a cold engine Refer to the engine starting procedure on page 74 for correct choke and throttle settings during starting The choke is fully on when the choke knob 1 is pulled completely out The choke is off when the knob is pushed completely in 64 FEATURES AND CONTROLS Manual Shift Shift Pedal The gear shift pedal is located in front of the left hand footpeg One full stroke of the pedal shifts the transmission to the next gear in the shifting sequence The pedal automatically returns to a horizontal position when released To upshift to a higher gear place the toe of your boot under the gear shift pedal and raise the pedal one full stroke To downshift place your foot on the gear shift pedal and depress the pedal one full stroke See page 67 AWARNING Shifting without releasing the throttle and disengaging the clutch could cause loss of control or vehicle overturn Always release the throttle and fully squeeze the clutch lever while shifting gears FEATURES AND CONTROLS Manual Shift The engine can be st
27. ONLY Operation is prohibited for anyone under 16 years of age This category S Sport ATV is a high performance vehicle intended for off road use only for sport type recreation and for competitive use by operators with advanced skills and substantial experience 14 SAFETY Operator Safety Know Your Vehicle As the operator of the ATV you are responsible for your safety the safety of others and the protection of our environment Read and understand your owner s manual which includes valuable information about all aspects of your ATV including safe operating procedures Safety Training When you purchased your new Polaris ATV your dealer offered a hands on safety training course covering all aspects of vehicle safety You were also provided with printed materials that explain safe operating procedures which you should review on a regular basis If your model is recommended for use by experienced operators only you also received a safety video Be sure to view it before operating the ATV If you purchased a used Polaris ATV from a party other than a Polaris dealer you can request this free safety training from any authorized Polaris dealer A Polaris ATV is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area Follow the recommended maintenance program outlined in your owner s manual This program is designed to ensure that all critical components on the ATV a
28. OPERATION Driving Safely Driving Through Water 4 CAUTION Major engine damage can result if the vehicle is not thoroughly inspected after operation in water Perform the services outlined in the maintenance chart If your vehicle becomes immersed or is operated in water that exceeds the footpeg level take it to your dealer for service before starting the engine NOTE Avoid operating the vehicle through deep or fast flowing water If you cannot avoid water that exceeds the recommended maximum depth go slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes If your vehicle becomes immersed and it s impossible to take it to a dealer before starting it follow the steps described on page 132 Have the vehicle serviced by your dealer at the first opportunity 87 OPERATION Driving Safely Driving Over Obstacles Be alert Look ahead and learn to read the terrain you re traveling on Be constantly alert for hazards such as logs rocks and low hanging branches AWARNING 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 88 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine intake or exhaust components as doing so may affect compliance wit
29. PAUL Owner s Manual for Vehicle Maintenance and Safety This Category S Sport ATV is a high performance ATV for off road use only It is for sport type recreational and competitive use by operators with advanced skills and substantial experience Operation is prohibited for anyone under 16 years of age Read this manual carefully ae I I W 2 1 1L 3 It contains important safety information The Way Out AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH ce s NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL ALWAYS USE NEVER USE AN APPROVED ON PUBLIC HELMET AND ROADS PROTECTIVE GEAR READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS Part No 9918783 PRINTED IN USA 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 Wear oe protection helmet and protective apparel POLARIS The Way Out AWARNING The engine exhaust from this product contains chemicals known to cause cancer birth de fects or other reproductive harm A card co
30. Polaris PS 4 oil Never mix oil brands 104 MAINTENANCE AND LUBRICATION Engine Oil Level Check the oil level before each use of the vehicle The dipstick 1 is located on the left side of the ATV 1 Position the ATV on a level surface 2 Start the engine and let it idle for one minute 3 Stop the engine and remove the dipstick Wipe it dry with a clean cloth 4 Reinstall the dipstick completely NOTE The dipstick must be screwed completely in to keep the angle and depth of the stick consistent 5 Remove the dipstick and check the oil level Maintain the oil level in the safe range 2 between the full and add marks Do not overfill 6 Reinstall the dipstick MAINTENANCE AND LUBRICATION Engine Oil Level If the ATV is used year round check the oil level frequently A rising oil level could indicate the accumulation of contaminates such as water or excess fuel in the bottom of the oil tank Water in the bottom of the tank can lead to engine damage and must be drained Water accumulation increases as outside temperature decreases 106 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 Do not allow the vehicle to be without oil and filter overnight Always replace the oil and filter within a few hours of draining the oil The suggested break in oil change should be perform
31. TV 166 TROUBLESHOOTING 167 173 Turning Around ona Hill 82 83 U USFS Approved Spark Arrestor 90 V VEHICLE IDENTIFICATION NUMBERS 6 7 Vehicle Immersion 132 133 Ww WARRANTY 178 180 WELCOME gio panir gan eka mot 3 4 Wheel Installation 140 Wheel Nut Torque Specifications 141 Wheel Removal 139
32. UN position NOTE Do not press the throttle lever while starting the engine Turn the ignition key to the ON position and press the start button to engage the starter Activate the starter for a maximum of five seconds releasing the button when the vehicle starts NOTE Excessive engagement may result in starter damage If the engine does not start wait five seconds after releasing the start button then activate the starter for another five seconds Repeat until the engine starts If the engine slows or stops position the choke knob half way in to allow proper engine warm up Vary the engine RPM slightly with the throttle to aid in warm up When the engine idles smoothly push the choke completely in 75 OPERATION Starting a Warm Engine Warm engines do not normally require the use of the choke Excessive use of the choke can cause the spark plug to become wet fouled 1 Place the transmission in neutral and lock the parking brake 2 Turn the fuel tank valve on sit on the vehicle and turn the engine stop switch to RUN 3 Disengage the clutch and press the start button to start the engine NOTE If the engine has cooled to a point where it does not readily start intermittent use of the choke button pulled half way out may be necessary NOTE If you believe the engine is over choked when warm push the choke lever completely in and depress the throttle lever fully while cranking to aid in starting Release the throttle leve
33. ables and lubricate Follow lubrication guidelines in the Maintenance Section of the service or owner s manual to completely grease and lubricate the entire vehicle with Polaris Premium All Season Grease Engine Anti Freeze Test engine coolant strength and add or change coolant if necessary Replace coolant every two years Storage Area Covers Set the tire pressure and safely support the ATV with the tires 1 2 off the ground Be sure the storage area is well ventilated and cover the machine with a genuine Polaris ATV cover NOTE Do not use plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation 165 CLEANING AND STORAGE Transporting the ATV Follow these procedures when transporting the vehicle 1 Turn off the engine and remove the key to prevent loss during transporting 2 Turn the fuel valve off 3 Be sure the fuel cap oil cap and seat are installed correctly 4 Always tie the frame of the ATV to the transporting unit securely as shown in the illustration using suitable straps or rope 5 Always place the transmission in first gear and lock the parking brake 166 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 Fuseable link See Polaris dealer for replacement Low battery voltage Recharge battery
34. andle remove the spark plug boot IMPORTANT Do not pull on the wire to remove the boot Doing so may cause a wire disconnection inside the boot 8 Using the spark plug wrench and handle rotate counterclockwise to remove the spark plug 9 Reverse all steps to install the spark plug and reassemble the body Torque the spark plug to 14 ft Ibs 19 Nm Be sure to reroute the vent hose 1 through the instrument panel Torque the tank mounting bolt to 9 ft Ibs 12 Nm 129 MAINTENANCE AND LUBRICATION Spark Arrestor AWARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death Do not perform service on the spark arrestor while the system is hot Exhaust system temperatures can reach 1000 F Allow components to cool sufficiently before proceeding Remove any combustible materials from the area Wear eye protection and leather work gloves Do not stand behind or in front of the vehicle while purging Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas Never go under the vehicle while it s inclined 130 MAINTENANCE AND LUBRICATION Spark Arrestor Periodically clean the spark arrestor to remove accumulated carbon 1 2 DNB Remove the three screws 1 and remove the arrestor 2 from the end of the muffler Use a non synthetic brush to clean the arrestor screen 3 A synthetic brush may melt if componen
35. arted when the transmission is in neutral or while in gear if the clutch is disengaged Place the stop switch in the RUN position then turn the key to ON If starting while in neutral the neutral indicator light should be on If it isn t disengage the clutch squeeze the clutch lever fully and shift the foot pedal to find neutral See page 65 When the vehicle is in neutral press the start button to start the engine If starting the engine while in gear 1 Apply the hand brake 2 Squeeze the clutch lever fully to disengage the clutch 3 Press the start button to start the engine Release the start button immediately when the engine starts 66 FEATURES AND CONTROLS Manual Shift Shifting Gears NOTE Always allow the engine to warm up before shifting gears 1 2 3 When starting from a stopped position with the transmission in neutral squeeze and hold the brake lever With the throttle closed not depressed squeeze the clutch lever to disengage the clutch Depress the gear shift pedal one full stroke to shift into first gear Release the brake lever Increase engine speed by gradually opening the throttle squeezing the throttle lever while slowly releasing the clutch lever As engine speed RPM increases in first gear simultaneously release the throttle disengage the clutch and shift to second gear by raising the gear shift pedal one full stroke Repeat this procedure to progressively upshift to additi
36. ate 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 controi LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS IF OWNER S MANUAL IS MISSING CONTACT A POLARIS DEALER FOR A REPLACEMENT 1997 2000 SAFETY 4 WARNING Operating this vehicle if you are under the age of 16 increases your chance of severe injury or death NEVER operate this vehicle if you are under age 16 7078253 Location C w Location B SAFETY Safety Decals and Locations NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH 7077920 Location E F Location F 10 Safety Decals and Locations MANUFAGTURED BY POLARIS IND INC DATE MIN conditions Do not operate vehicle without pre filter Operation of this vehicle without engine breather filter s can cause engine damage Consult owner s manual or dealer for details 4 WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE IN
37. ating over obstacles could cause loss of control or overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles _Avoid operating over large obstacles such as rocks and fallen trees when possible If unavoidable use extreme caution and always follow proper procedures as outlined in the owner s manual 44 SAFETY Operator Safety A 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 45 SAFETY Operator Safety 46 A 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 its unavoidable to enter water that exceeds the recommended maximum depth see page 87 travel slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Always test the brakes after leaving water If necessary apply them several times to let
38. clean your ATV is with a garden hose and a pail of mild soap and water Use a professional type washing mitten cleaning the upper body first and the lower parts last Rinse with water frequently and dry with a chamois to prevent water spots NOTE If warning and safety decals are damaged contact your a Polaris dealer for free replacement 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 160 CLEANING AND STORAGE 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 chemicals will damage plastic surfaces Use caution when using these products near plastic surfaces 161 CLEANING AND STORAGE See page 175 for the part numbers of Polaris products Storage Recommendations CAUTION Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur Never start the engine during the storage period Clean the Exterior Make necessary repairs and then clean the ATV thoroughly as outlined on page 160 Stabilize the Fuel Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer to the fuel tank following the instructions on the container for the recommended amount Fill the fuel tank with fuel Allow 15
39. cy action This may include quick dismounting of the vehicle AWARNING 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 Use extreme caution when operating on hills and follow all procedures outlined in the owner s manual 80 OPERATION Driving Safely Driving Across Hills AWARNING 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 If you enter into a situation where sidehilling is unavoidable 1 Slow down 2 Lean into the hill transferring your upper body weight toward the hill while keeping your feet on the footpegs 3 Steer slightly into the hill to maintain vehicle direction NOTE If the vehicle begins to tip quickly turn the front wheels downhill if possible or dismount on the uphill side immediately 81 OPERATION Driving Safely Turning Around on a Hill AWARNING Improper hill climbing procedures could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 25 maximum Use extreme caution when operating on hills and follow proper operating procedures outlined in the owner s manual If the vehicle stalls while climbing a hill ne
40. d injury Select an approved helmet that meets or exceeds your state s safety standards and bears either the Department of Transportation DOT label the American National Standards Institute label ANSI z90 1 or the Snell Memorial Foundation label 12 SAFETY Safe Riding Gear 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 SAFETY Operator Safety AWARNING Failure to follow the warnings contained in this manual can result in severe injury or death A Polaris ATV is not a toy and can be hazardous to operate This vehicle handles differently than other vehicles 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 your Polaris ATV Operator Restrictions This vehicle is an ADULT VEHICLE
41. d inside the cab under the front cover 4 Gently pull the cab forward to remove the cab and disengage it from the stand offs on the fuel tank 5 Reverse all steps to reinstall the front cab 124 MAINTENANCE AND LUBRICATION Spark Plugs e Use NGK DCPRSE spark plugs e Proper electrode gap is 035 90 mm e Spark plug torque is 14 ft Ibs 19 Nm CAUTION Using non recommended spark plugs may result in serious engine damage and may void your emission related warranty 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 AWARNING A hot exhaust system and engine can cause serious burns Wear protective gloves when removing a spark plug for inspection Allow components to cool before continuing 125 MAINTENANCE AND LUBRICATION Spark Plugs 1 Normal The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service NOTE The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetion adjustments 2 Wet Fouled The wet fouled insulator tip is black A damp oil film c
42. e plug Torque to 14 ft lbs 19 Nm Place shop towels beneath the oil filter Remove the three cover bolts and remove the cover Pull out the oil filter NOTE A spring located behind the filter may pop out as the filter is removed The spring must be reinstalled with the new filter Using a clean dry cloth clean the filter sealing surfaces Step 12 109 MAINTENANCE AND LUBRICATION Oil and Filter Change 14 Replace the o ring in the cover 15 Lubricate the gasket on the new filter with a film of fresh engine oil 16 Reinstall the spring and install the new filter with the open end facing outward 17 Install the cover and torque the bolts to 72 78 in Ibs 8 9 Nm NOTE The long bolt must be placed in the forward hole Step 14 110 MAINTENANCE AND LUBRICATION Oil and Filter Change 18 Remove the dipstick and fill the oil tank with 2 quarts 1 9 I of recommended oil 19 Place the transmission in neutral and set the parking brake 20 Start the engine and let it idle for one to two minutes Stop the engine and inspect for leaks 21 Re check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick 22 Dispose of the used filter oil and shop towels properly 111 MAINTENANCE AND LUBRICATION Air Filter Systems 1 Unlatch and remove the seat 2 Loosen the intake duct clamp 1 on the carburetor 3 Pull the duct 2 off the carburetor 4
43. ed after one hour of operation or after the first tank of fuel whichever comes first Perform the next oil and filter changes every 10 hours or every six months whichever comes first Severe use operation requires more frequent service Severe use includes continuous duty in dusty or wet conditions and operating in very cold or very hot weather Severe use cold weather riding is all riding below 10 F 12 C and riding between 10 F and 40 F 12 and 4 C when most trips are slow speed and less than 5 miles 107 MAINTENANCE AND LUBRICATION Oil and Filter Change 1 Place the vehicle on a level surface 2 Clean the area around the oil tank 1 and crankcase 2 drain plugs with clean shop towels 3 Run the engine for two to three minutes until warm then stop the engine 4 Place a drain pan beneath the oil tank and remove the drain plug CAUTION Hot oil can cause serious burns to skin Do not allow hot oil to contact skin 5 Allow the oil to drain completely 6 Replace the sealing washer and reinstall the plug Torque to 14 ft Ibs 19 Nm NOTE The sealing surfaces on drain plugs oil tank and crankcase should be clean and free of burrs nicks or scratches 108 MAINTENANCE AND LUBRICATION Oil and Filter Change J 8 9 10 11 12 13 Place a drain pan beneath the crankcase and remove the drain plug Allow the oil to drain completely Replace the sealing washer and reinstall th
44. embly Replacement 1 Remove the wire harness connector from the headlights 2 Remove the front cab see page 124 2 Position the cab upside down on a soft protective surface to prevent scratching 3 Remove the small adjuster bracket 1 and install it on the new lamp 4 Remove the large pivot bracket 2 and remove the headlamp 119 MAINTENANCE AND LUBRICATION Lights Headlight Assembly Replacement 5 Install the new headlamp by inserting the outboard pivot pin in the hole of the mounting tab on the cab 6 Install the adjuster bracket onto the inboard pivot pin of the headlamp 7 Adjust for approximately 1 16 clearance between the bracket and the edge of the headlight Tighten the mounting screws IMPORTANT Be sure the bracket is 90 degrees to the pivot pin so the lamp can move freely 8 Install the adjusting screw leaving it loose so the headlight can be adjusted 9 Reinstall the front cab and connect the wire harness to the headlamp 10 Adjust the lamps as needed then tighten the adjuster screw See page 122 120 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 cover mounting screws 1 Remove the lens cover 2 and gasket and set aside for f reassembly 2 Remove the lamp 3 and replace it with a new lamp Test the taillight brakelight to see that it s wo
45. er or dirt contamination from grease fittings and other critical components Emission Control System Service California 4 Cycle W Dealer service item Use Polaris Premium All Season Grease or grease conforming to NLGI No 2 such as Conoco Superlube M or Mobilegrease Special 92 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule em Houses Freauency Remarks Brake systems fluid Pre Ride Pre Ride Inspect maintain fluid level between fill lines see page 60 change every 200 mi or 24 months 8s Pede rre iae reset wnesstua mus inspect hen Fametasenes Preside Freue inspect tighten Air filter and Pre Ride Pre Ride Inspect clean k Pre cleaner C oom Piae Pena mepet evel addasnecded Trot Pene Pena Fio properes e Enginstransmissin of PreFide Pre Ride Fillo proper levei wih Polaris Sa ol roe Pride PreFide Check operation De cun Prema PreFide Check operation andadhustnent E tans fene PreFide Check operation Engine stop switch Pede Pre Fide Check operation 93 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule AWARNING Improperly performing the procedures marked with a m could result in component failure and lead to serious injury or death Have a Polaris dealer perform th
46. ermit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course Always avoid operating an ATV on paved surfaces including sidewalks driveways parking lots and streets 18 SAFETY Operator Safety 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 ATV Never operate at excessive speeds Travel at speeds appropriate for the terrain visibility and operating conditions and your experience Never attempt wheelies jumps or other stunts Always inspect your ATV before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and schedules outlined in your owner s manual Always keep both hands on the handlebars and both feet on the footpegs of the ATV dur ing operation Always travel slowly and use extra caution when operating on unfamiliar terrain Be alert to changing terrain conditions SAFETY Operator Safety 20 Never operate on excessively rough slippery or loose terrain Always follow proper turning procedures as described in this manual Practice turning at low speeds before attempting to tur
47. ese services Fem Houses Frequency Remarks ponents p Air box sediment tubes Drain deposits when visible Headlamp Pre Ride Pre Ride Check daily apply Polaris dielectric grease to connector when replaced Tail lamp brake lamp Pre Ride Pre Ride Check daily apply Polaris dielectric grease to socket when replaced A arm ball joint Pre Ride Pre Ride Check freeplay daily have dealer replace if wheel moves excessively 94 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule CO pem Fourmies Frequency Remaris Air filter Weekly Weekly Inspect replace as needed k main element Oil Change 10 hrs 6 months Perform break in service at one hour change oil more often in very cold or hot weather or under severe use Oil Filter 10 hrs 6 months Replace with oil change perform break in gt oil filter change at one hour IW Brake pad wear Monthly Inspect periodically Beey ams wontiy ceckteminas cea Engine breather filter 20 hrs Monthly Inspect clean as needed E General lubrication Lubricate all fittings pivots cables p More often under severe use such as dirty or wet conditions Emission Control System Service California Wi Dealer service item Polaris Premium All Season Grease 95 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule AWARNING Improperly performing the procedures marked with a m
48. essary through the radiator filler neck 3 Replace the pressure cap NOTE Use of a non standard pressure cap will not allow the recovery system to function properly Contact your dealer for the correct replacement part 116 MAINTENANCE AND LUBRICATION Lights When servicing a halogen lamp don t touch the lamp with bare fingers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp AWARNING 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 117 MAINTENANCE AND LUBRICATION Lights Headlight Lamp Replacement 1 Remove the wire harness connector from the back of the headlight 2 On the left headlamp grasp the bulb housing and turn it counterclockwise 1 to remove the bulb On the right headlamp turn the bulb housing clockwise 2 to remove the bulb 3 Apply dielectric grease to the light bulb socket before installing the new bulb Install the replacement bulb into headlight housing and rotate clockwise firmly NOTE The bulb must be positioned so the harness installs into the lamp at outer side 4 Reinstall the connector to the back of the headlight 118 MAINTENANCE AND LUBRICATION DA Lights Headlight Ass
49. evel between the MIN and MAX marks See page 60 142 ADJUSTMENTS Brakes 1 Always maintain the brake fluid at an adequate level see page 60 Check the brake system for fluid leaks Check the brakes for excessive travel or spongy feel Check the friction pads for wear damage and looseness Check the security and surface condition of the disc Qv Uv cota P9 Inspect the rear brake disc spline and pad wear surface for excessive wear NOTE Pads should be changed when worn to 3 64 1 cm or 3 64 1 cm about the thickness of a U S dime 143 ADJUSTMENTS AWARNING 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 Predator is designed for a neutral toe setting 1 Set the handlebars in a straight ahead position Use tie straps to secure the handlebars so they can t move NOTE The steering arm can be used as an indicator of whether the handlebars are straight The arm should always point straight back from the steering post 2 Place stands 1 in front of the vehicle perpendicular to the rear tires See illustration 144 ADJUSTMENTS Toe Alignment 3 Tie an elastic string 2 around the stands making sure the string just touches the side
50. h state and local noise level requirements Spark Arrestor Your Polaris vehicle has a spark arrestor that was tested and approved in accordance with the USDA Forest Service Standard 5100 1C Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system The system does not allow the blow by gases to enter the atmosphere 89 EMISSION CONTROL SYSTEMS Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design including factory set carburetion and ignition The engine and related components must be maintained at Polaris specifications to achieve optimal performance Adjustment to engine idle is the only adjustment Polaris recommends that the operator perform Any other adjustments should be performed by an authorized Polaris dealer The emissions label 1 is located on the recoil cover 90 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule 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 following pages And to help you perform routine maintenance a tool kit is provided in the storage compartment under the seat I
51. hibition driving 33 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the owner s manual 34 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Removing hands from the handlebars or feet from the footpegs 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 footpeg 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 footpegs of the ATV during operation 35 SAFETY Operator Safety A 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 conditio
52. hicle to the ground 5 Torque the wheel nuts according to the wheel nut torque specifications chart NOTE Any nuts that have a cotter pin installed must be serviced by an authorized Polaris dealer 140 MAINTENANCE AND LUBRICATION Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loosened for maintenance service Bolt Size Specification Front 3 8 25 ft Ibs 84 Nm Rear 3 8 25 ft Ibs 34 Nm 141 ADJUSTMENTS Brakes Under normal operation the diaphragm extends into the reservoir as fluid level drops If the fluid level is low and the diaphragm is not extended a leak is likely and the diaphragm should be replaced Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation Do not overfill See page 60 The front brakes are hydraulic disc brakes They re activated by squeezing the brake lever toward the handlebar The rear brake is a hydraulic disc brake activated by the foot brake pedal Both brakes are self adjusting but the following checks are recommended to keep the brake systems in good operating condition Check more often if brakes are used heavily under normal operation AWARNING Overfilling the master cylinder will result in brake failure Without room to expand the excess fluid will cause the brakes to apply automatically which could result is serious injury or death Always maintain the fluid l
53. ing could cause loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner s manual 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 i high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill SAFETY Operator Safety A 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 84 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 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Improperly crossing hills and turning on hills WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of co
54. is stored or parked Make sure the vent line is in good condition and is routed properly 69 OPERATION Break In Period Careful treatment of a new engine and transmission will result in more efficient performance and longer life for both The break in period for your new Polaris Predator is defined as the first one hour of operation followed by an additional two hours of cautious operation or the time it takes to use the first full tank of gasoline No single action on your part is as important as following the procedures for a proper break in Perform the following procedures carefully CAUTION Excessive heat build up during the first three hours of operation may damage close fitted engine and transmission parts Do not operate at full throttle or high speeds for extended periods during the first three hours of use Use of any lubricants other than those recommended by Polaris may cause serious engine damage We recommend the use of Polaris lubricants for your vehicle 70 OPERATION Break In Period 1 2 Fill the fuel tank with gasoline See page 64 Check the oil level on the dipstick See page 105 Add oil if necessary to maintain the level between the safe and add marks Allow the engine sufficient time to warm up before operating Drive slowly at first Select an open area that allows room to familiarize yourself with vehicle operation and handling Vary the throttle positions Do not operate at sustained idle
55. location This policy does not apply to Safety Recalls 182 WARRANTY Exported Vehicles 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 ve hicle 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 autho rized to perform the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of the destination country before you move Vehicles importation rules vary considerably from country to country You may be required to present documentation of your move to Polaris Industries in order to continue your warranty coverage You may also be required to obtain documentation from Polaris Industries in order to register your ve hicle in your new country 183 WARRANTY Exported Vehicles How to Get Service If Purchased From A Private
56. low these precautions 1 Proceed directly downhill 2 Transfer your weight to the rear of the vehicle 3 Slow down 4 Shift to the lowest gear possible while maintaining a safe speed 5 Apply the foot brake slightly to aid in slowing AWARNING Excessive speed can cause loss of control and lead to serious injury or death Always operate slowly when traveling downhill 84 OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 Turn the engine off 2 Place the transmission in first gear 3 Lock the parking brake 4 Always block the rear wheels on the downhill side See illustration 5 Shut off the fuel supply sa E 85 OPERATION Driving Safely Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the level of the footpegs 1 Follow these procedures when operating through water 1 Determine water depths and current before crossing 2 Choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles if possible 4 After crossing dry the brakes by applying light pressure to the lever until braking action is normal After running the vehicle in water it s critical to have it serviced as outlined in the maintenance chart See page 91 The engine oil and all grease fittings need special attention 86
57. n 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 terrain carefully before ascending a hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes Never go over the top of a hill at high speed Always follow proper procedures for going downhill and for braking on hills Check the terrain carefully before you start down a hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when possible SAFETY Operator Safety Always follow proper procedures for crossing the side of a hill Avoid hills with exces sively 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 turning technique outlined in this manual Avoid crossing the side of a steep hill when possible Always use proper procedures if you stall or roll backwards while climbing a hill To avoid stalling maintain a steady speed when climbing a hill If yo
58. n the ATV for your protection Read and follow the instructions of the decals on the ATV carefully If any of the decals depicted 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 Safety Decals and Locations 4 amp WARNING eNever operate this vehicle on HILLS steeper than 25 degrees 25 To prevent flipover on hilly terrain when going up or down use throttle and brakes gradually eREVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent flipover avoid sudden braking or sharp turns ePARKING BRAKE may relax when used for more than 5 minutes When parking on grades leave ATV in gear This ATV may exceed the performance of other ATVs you may have ridden in the past This category S Sport ATV is a high performance vehicle for off road use only in sport type recreation and competitive use by operators with advanced skills and substantial experience 7170906 Location A 4 WARNING Improper ATV use can result in SEVERE INJURY or DEATH DO ALWAYS USE NEVERUSE NEVERCARRY NEVER USE AN APPROVED ONPUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER oper
59. nce of a severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants SAFETY Operator Safety A 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 31 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Operating the ATV at excessive speeds WHAT CAN HAPPEN Excessive speed increases the operator s chance of losing control of the ATV which can result in an accident causing severe injury or death 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 32 SAFETY Operator Safety A 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 ex
60. ner s manual For more information about the training course contact an authorized ATV dealer or call Polaris at 1 800 342 3764 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Failure to follow the skill and experience recommendations for this ATV WHAT CAN HAPPEN Severe injury and or death could occur if a beginner or inexperienced driver operates this ATV HOW TO AVOID THE HAZARD Only operators with advanced skills and substantial experience should operate this ATV 25 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV WHAT CAN HAPPEN Severe injury and or death could occur if a child under the minimum age recommendation operates this 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 Only operators with advanced skills and substantial experience should operate this ATV 26 SAFETY Operator Safety A 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
61. ng page if the chain needs adjustment 147 ADJUSTMENTS Chain Tension 1 2 3 4 148 Loosen the two eccentric locking bolts Insert a pin punch into the eccentric axle housing Roll the vehicle ahead or back to adjust chain slack to the proper dimension Tighten the eccentric locking bolts to 35 ft lbs 47 5 Nm Step 2 n Proper Splicelink Clip Opening Position Step 1 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 Suspension Settings Setting Compression Damping Rebound Damping Clicker Position 1 20 clicks from closed Clicker Position 4 10 clicks from closed Clicker Position 8 Fully closed 149 ADJUSTMENTS Front Suspension The front suspension preload may be adjusted to suit different riding conditions and operator weight AWARNING Uneven adjustment may cause poor handling of the ATV which could result in an accident and serious injury or death Always adjust both the left and right spring preloads equally or have your Polaris dealer perform the adjustments 150 Front Suspension Spring Preload 1 2 Raise and safely support the front of the ATV off the ground to allow the suspension to fully extend
62. ning a sealed battery is keeping it fully charged The battery included with your ATV is sealed and the sealing strip cannot be removed Use a voltmeter or multimeter to measure DC voltage A fully charged battery will register 12 8 V or higher If the voltage is less than 12 8 volts recharge the battery NOTE The Polaris Battery Tender battery charger can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point see page 175 When using an automatic charger such as the Polaris Battery Tender refer to the manufacturer s instructions for recharging When using a constant current charger use the guidelines on the following page for recharging AWARNING An overheated battery could 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 136 MAINTENANCE AND LUBRICATION Battery Charging Sealed Battery NOTE Always verify battery condition before and 1 2 hours after charging State of Voltage Charge Time Charge Using constant current charger standard amps specified on top of battery 100 12 8 13 0 volts None check at None required 3 mos from date of manufacture 75 100 12 5 12 8 volts May need slight charge 3 6 hours if no charge given check in 3 months 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 5
63. ns SAFETY Operator Safety A 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 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 SAFETY Operator Safety A 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 38 SAFETY Operator Safety A 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 degrees 25 Practice on smaller hills before attempting large hills 39 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Improper hill climb
64. ntaining important ATV safety information should be attached to the owner s manual on the next page If you cannot locate this card or if it has been removed please call 1 800 342 3764 for assistance We ve created a web site just for YOU e Technical tips e New product introductions e Event schedules e Parts and Service Manual information e Exciting details about The Way Out Check it out www polarisindustries com owner POLARIS The Way Out Polaris Polaris The Way Out and Workmobiles are registered trademarks of Polaris Industries Inc Copyright 2003 Polaris Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited Printed in U S A 2 WELCOME Thank you for purchasing a Polaris vehicle and welcome to our world wide family of Polaris owners We proudly produce an exciting line of utility and recreational products Polaris Recreational Vehicles Snowmobiles All terrain vehicles ATVs
65. ntrol or overturn HOW TO AVOID THE HAZARD Never attempt to turn the w ATV around on any hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 82 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 A WARNING POTENTIAL HAZARD Stalling rolling or improperly dismounting while climbing a hill WHAT CAN HAPPEN The vehicle could overturn HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill If all forward speed is lost Keep your weight uphill Apply front brakes gradually When fully stopped apply rear brake as well then lock the parking brake If the ATV begins rolling backwards Keep weight uphill Never apply engine power Never apply the rear brake while rolling backwards Apply the front brake gradually When fully stopped apply the rear brake as well and then lock the parking brake Dismount on uphill side or to either side if ATV is pointed straight uphill Turn the ATV around and remount following the procedure described in the owner s manual See page 82 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Oper
66. olant Level Radiator 116 Coolant Level Recovery Bottle 115 Cooling System 114 115 D Driving Across Hills 81 Driving Downhill 84 Driving on Slippery Surfaces 79 Driving Over Obstacles 88 Driving Procedures 77 Driving Safely 71 88 Driving Through Water 86 87 Driving Uphill 80 E Electrical Switches 52 53 Electronic Throttle Control 57 Engine Cooling System 116 Engine Oil Level 105 106 Equipment Modifications 23 F FEATURES AND CONTROLS 52 68 Poot Brake 2 9 58 Index F FrontSuspension 150 151 Fuel Filter sera eem ern 64 Fuel Safety ec mu nrar arh 69 Fuel Tank s eie etm ra ferum 64 Fuel Valve s 4 e eat aie cin eter 63 H Handlebars heei ar age 8 og agen eee 157 Headlight Adjustment 122 Headlight Assembly Replacement 119 120 Headlight Lamp Replacement 118 J Jetting Chart 0 177 K K turn 1 seen tem Pee 82 L Light Switches 55 Lights ios ts fe ews at 54 117 122 Lubrication Points 97 Lubrication Recommendations 104 185 Index M MAINTENANCE AND LUBRICATION 91 141 Maintenance Record 102 103 Making Tumis a v2 06 Syst cages 78 Manual Shift 65 68 Master Cylinder 60 N NOISE CONTROL SYSTEM
67. onal gears Use the same procedure to downshift 67 FEATURES AND CONTROLS Manual Shift Deceleration To slow or stop the ATV release the throttle lever and apply the brakes smoothly and evenly As the vehicle slows and engine RPM decreases disengage the clutch and shift to a lower gear NOTE Be sure the engine RPM has sufficiently decreased before shifting to a lower gear AWARNING Improper use of the brakes or shifting when the engine RPM is too high can cause the tires to lose traction or stop rotating which could lead to loss of control accident and injury It could also cause engine or drive train damage Make sure the engine RPM has sufficiently decreased before shifting to a lower gear 68 OPERATION Fuel Safety AWARNING Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always refuel with the engine stopped and outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Turn the fuel valve off whenever the ATV
68. overs the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended oil improper use of the choke or incorrect carburetion adjustments 126 MAINTENANCE AND LUBRICATION Spark Plugs Spark Plug Removal and Replacement 1 Remove the side panels and front cab see pages 123 124 2 Turn the fuel valve to OFF AWARNING A hot ember on the ATV could cause fuel to ignite Allow all components to cool sufficiently before accessing the spark plug Always exercise extreme caution when handling fuel systems and gasoline Always heed the fuel warnings on page 69 127 MAINTENANCE AND LUBRICATION Spark Plugs Spark Plug Removal and Replacement 3 128 Move the fuel valve hose clamp 1 forward and gently remove the hose from the fuel valve fitting on the gas tank Remove the vent hose 2 from the instrument panel taking note of the hose routing for reinstallation Remove the tank mounting bolt 3 at the rear of the gas tank Move the tank rearward and upward over the engine Slowly remove the tank and be careful not to catch any hoses wires or other components Place the tank on a ELM stable surface or work bench Be sure to protect the valve from contamination or damage MAINTENANCE AND LUBRICATION Spark Plugs Spark Plug Removal and Replacement 7 Using the forked end of the spark plug wrench h
69. r immediately after the engine starts 4 Ifthe engine does not start review the engine troubleshooting information beginning on page 167 If all conditions are favorable and the engine still does not start see your Polaris dealer for service 76 OPERATION Driving Safely Driving Procedures 1 2 3 Sit upright with both feet on the footpegs and both hands on the handlebars Start the engine and allow it to warm up then shift the transmission into gear See page 67 Check your surroundings and determine your path of travel t Release the parking brake dl doi Slowly depress the throttle with your right AN thumb while slowly releasing the clutch oe ISS Y ANO pum lever to begin driving 7 JL Drive slowly Practice maneuvering and using the throttle clutch and brakes on level surfaces 77 OPERATION Driving Safely Making Turns Your ATV is equipped with a solid rear axle which drives both rear wheels equally at all times The wheel on the outside of the turn travels a greater distance than the inside wheel when turning and the inside tire slips traction slightly To turn steer in the direction of the turn leaning your upper body to the IK inside of the turn while supporting your weight on the o KM o outer footpeg This technique alters the balance of 5 7 f T traction between the rear wheels allowing the turn to ve be made smoothly UT 2 REA Mec o7 NOTE Practice making turns at
70. r of the spark plug while performing the following steps 5 Intermittently and briefly touch the starter button in half second intervals to SLOWLY rotate the engine three or four times Water will eject from the spark plug hole 6 Press and hold the starter button for 10 second intervals for about one minute or until water vapor is no longer ejecting from the spark plug hole 7 Check the oil level on the dipstick If the level is higher than the pre ride inspection level water has entered the oil tank Do not start the engine Tow the ATV and see your dealer If the oil level is unchanged from the pre ride inspection level replace the spark plug start the engine and move the ATV promptly to a trailer or towing vehicle CAUTION If water isn t removed promptly from a submerged ATV rust will form in precision components gears bearings the cylinder and other areas and result in serious engine damage Always see your dealer promptly after an ATV has been submerged 133 MAINTENANCE AND LUBRICATION Battery The YUASA 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 Keep battery terminals and connections free of corrosion If cleaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop
71. r operate the ATV with a spongy feeling brake lever 59 FEATURES AND CONTROLS Master Cylinder The master cylinder 2 is located on the right hand handlebar The brake fluid level should be checked before each ride The fluid level can be seen through the indicator window 3 on the top of the master cylinder This eye will appear dark when the fluid level is full When fluid needs to be added the eye will be clear NOTE When checking the fluid level the ATV must be on level ground with the handlebars straight If the fluid level is low add DOT 3 brake fluid only Do not overfill See page 175 for the part numbers of Polaris products AWARNING Overfilling the master cylinder will result in brake failure Without room to expand the excess fluid will cause the brakes to apply automatically which could result in serious injury or death Always maintain the fluid level between the MIN and MAX marks After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of accident or severe injury See page 142 60 FEATURES AND CONTROLS Parking Brake AWARNING Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death Always check to be
72. re thoroughly inspected at specific intervals SAFETY Operator Safety The following two pages identify signal words and symbols that appear in this manual Your safety is involved when these words and symbols are used Become familiar with their meanings before reading the manual A The safety alert symbol on your vehicle or in this manual alerts you to the potential for personal injury AWARNING The safety alert warning indicates a potential hazard that may result in serious injury or death 16 SAFETY Operator Safety 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 result in damage to the vehicle NOTE A note will alert you to important information or instructions SAFETY Operator Safety AWARNING 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 Beginners should receive training from a certified instructor Contact an authorized Polaris ATV dealer or call Polaris at 1 800 342 3764 to find out about the training courses nearest you Never allow anyone under 16 years of age to operate this ATV Never p
73. rking 4 Reinstall the gasket and lens cover Sa 121 MAINTENANCE AND LUBRICATION Lights Headlight Adjustment 1 Position the ATV on a level surface with the headlight approximately 25 ft 7 6 m from a flat wall 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 3 Start the engine and turn the headlight switch to high beam O 4 Observe the headlight aim on the wall The most 2 L Fi intense part of the headlight beam should be aimed 2 5 1 cm below the mark placed on the wall NOTE Include rider weight on the seat when measuring 5 Loosen the pivot screw 1 and adjust the beam to the desired position 6 Tighten the screw and torque to 27 in lbs 3 Nm 122 MAINTENANCE AND LUBRICATION Side Panel Removal 1 2 3 Rear Cab Removal 1 2 Unlatch and remove the seat Remove the four screws 1 securing the side panel Remove the side panel Unlatch and remove the seat Remove the four bolts 2 on the rear fenders of the cab and the two bolts 3 washers and grommets 4 on the top of the cab Remove the two screws 5 from the rear cab supports Remove the cab 123 MAINTENANCE AND LUBRICATION Front Cab Removal 1 Remove the screws and washers 1 from the front left hand and right hand cab mounts 2 Remove the wire harness connector from the headlights 3 Loosen the screw 2 locate
74. s dirty or wet conditions Emission Control System Service California Wi Dealer service item Polaris Premium All Season Grease 100 NOTES 101 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance Maintenance Servicing Interval Dealer Performed or Person MAINTENANCE AND LUBRICATION Periodic Maintenance Record Maintenance Servicing Servicing Interval Date Dealer Performed or Person MAINTENANCE AND LUBRICATION Lubrication Recommendations Performance Synthetic 4 Stroke PS 4 Oil Polaris highly recommends the use of Polaris PS 4 or a similar oil designed for use in 4 stroke manual clutch ATV and motorcycle applications PS 4 has been specifically formulated for use in high performance engines PS 4 is a fully synthetic high performance multi viscosity oil designed to provide the ultimate in lubrication performance and protection and prolonged clutch life NOTE See page 175 for the part numbers of Polaris products PS 4 oil possesses unsurpassed film strength over the widest possible temperature range It resists viscosity and frictional breakdown in ambient temperatures from 40 F to 120 F 40 to 49 C Its exceptional frictional properties result in more efficient operation more power output and lower fuel consumption CAUTION Mixing brands or using a non recommended oil may cause serious engine damage Polaris recommends the use of
75. slow speeds before x attempting to turn at faster speeds TE ee ieee AWARNING Turning at sharp angles or at excessive speeds can result in vehicle overturn and lead to serious injury or death Avoid turning at sharp angles Never turn at high speeds 78 OPERATION Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel or during freezing weather follow these precautions 1 Slow down when entering slippery areas 2 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids m ph ii AJ 3 Correct a skid by turning the handlebars in the Ki DA T AS oO direction of the skid and shifting your body weight ENO LI forward B LEN AWARNING 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 especially when downshifting 79 OPERATION Driving Safely Driving Uphill Whenever traveling uphill follow these precautions 1 Always travel straight uphill 2 Avoid steep hills 25 maximum 3 Keep both feet on the footpegs and transfer your weight forward 4 Proceed at a steady rate of speed and throttle opening 5 Be alert and prepared to take emergen
76. t s located in front of the right hand footpeg 2 and is operated by the right foot If the rear wheels slide while using the foot brake reduce brake pedal pressure to brake the wheels without skidding Check the brake fluid level frequently for the foot brake system The reservoir is located behind the right side panel Maintain the fluid level between the MIN and MAX marks AWARNING Aggressively applying the foot brake when backing down a hill may cause rear tipover which could result in serious injury or death Use caution when applying the foot brake Do not aggressively apply the foot brake when going forward The rear wheels may skid and slide sideways causing loss of control and serious injury or death 58 FEATURES AND CONTROLS Brake Lever The Predator ATV has a single brake lever for the front 2 1 brakes It s located on the right handlebar The front 3 brakes are applied by squeezing the brake lever 1 p d toward the handlebar The front brakes are hydraulically activated disc type brakes Always test brake lever travel and master cylinder fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before riding Contact your dealer for proper diagnosis and repairs AWARNING Operating the ATV with a spongy brake lever can result in loss of braking which could cause an accident Neve
77. tems included in the kit are e Spark plug socket and handle Open end wrench 1 2 in and 10 mm Torx T25 screwdriver e wrench 1 27 Tire pressure gauge Maintenance intervals are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use such as operation in wet or dusty areas should be inspected and serviced more frequently Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use genuine Polaris parts available from your Polaris dealer NOTE Service and adjustments are critical If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations 91 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Hours of operation are based on a 10 mph average For example if a service is due at 20 hours the equivalent odometer reading would be 200 miles Perform all services at whichever reading is reached first hours of operation miles logged or time elapsed Perform all services more frequently under severe use AWARNING 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 Maintenance Chart Key p Perform these operations more often under severe use such as in dirty or wet conditions to purge wat
78. ter NOTE Always follow the manufacturer s mixing recommendations for the freeze protection required in your area 114 MAINTENANCE AND LUBRICATION Engine Cooling System Coolant Level The recovery bottle 1 is located on the left side of the machine under the front fender The fluid level must be maintained between the minimum and maximum marks on the bottle when the fluid is cool As coolant operating temperature increases the expanding heated excess coolant is forced out of the radiator past the pressure cap and into the recovery bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the tank past the pressure cap and into the radiator NOTE Some coolant level drop on new machines is normal as the system is purging itself of trapped air Observe coolant levels and maintain as recommended by adding coolant to the recovery bottle 115 MAINTENANCE AND LUBRICATION Engine Cooling System AWARNING Escaping steam can cause severe burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the cap Radiator Coolant Level NOTE This procedure is required only if the cooling system has been drained for maintenance and or repair However if the recovery bottle has run dry inspect the level in the radiator and add coolant if necessary 1 Remove the pressure cap 2 Using a funnel slowly add coolant as nec
79. that axle nuts are secured by cotter pins A arm ball joints Check freeplay If the tire moves excessively see your Polaris dealer for replacement before operating Loose parts Visually inspect the vehicle for any damaged components or loose nuts bolts or fasteners Riding gear Wear a helmet goggles and protective clothing 73 OPERATION Starting a Cold Engine AWARNING CAUTION Engine exhaust contains poisonous Operating the vehicle immediately carbon monoxide and can cause loss after starting could cause engine of consciousness resulting in severe damage Allow the engine to warm injury or death Never run an engine up for several minutes before in an enclosed area operating 1 Place the transmission in neutral lock the parking brake and disengage the clutch Make sure the fuel valve is on 2 Sit on the ATV and pull the choke knob 1 out until it stops NOTE If the knob doesn t stay where positioned increase the tension by rotating the tension adjusting nut clockwise 74 OPERATION Starting a Cold Engine NOTE The variable choke is fully on when the knob is pulled completely out The choke is off when the knob is pushed completely in The choke can be adjusted gradually depending on how much choke is needed for starting Be sure the choke is off during operation as excess fuel washing into the engine oil will increase wear on engine components 3 4 Move the engine stop switch to the R
80. transmission in neutral 3 Adjust the carburetor idle screw 1 either in or out until the desired idle RPM is reached Turning the screw in clockwise will raise RPM Turning the screw out counterclockwise will lower RPM 158 ADJUSTMENTS Carburetor Idle RPM If the vehicle is to be operated at various altitudes and temperatures certain adjustments can be made to improve its operation and driveability Above 6000 feet 1800 m the engine air fuel mixture becomes overly rich An engine loses approximately 3 of its power for each 1000 foot 304 8 m increase in elevation Although this power cannot be regained changes to the carburetor and drive system can be made to allow more efficient operation NOTE Contact your dealer for altitude adjustments Your dealer has the training and special tools required to perform these modifications e Carburetor re jetting can be performed to compensate for altitude and or temperature changes 159 CLEANING AND STORAGE See page 175 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 CAUTION Do not use a high pressure washer for washing the ATV Serious damage will result to wheel bearings chains transmission seals body panels brakes and decals The best and safest way to
81. ts are warm Inspect the screen for erosion and replace if necessary Remove and inspect the gasket Replace if worn or damaged Reinstall the gasket and arrestor Torque screws to 50 in Ibs 5 6 Nm Do not over tighten 131 MAINTENANCE AND LUBRICATION Vehicle Immersion If your ATV has been submerged or overturned in water deeper than the footpeg level it s critical to dry it promptly and properly before starting the engine CAUTION Do not start the engine after an ATV has been in water that exceeds the recommended depth Serious engine damage WILL occur Tow or trailer the ATV to your dealer for service In an emergency perform the temporary drying out procedure outlined below which will allow short term operation only to drive the ATV to a trailer or towing vehicle Do not perform the following procedures if you don t feel completely capable or if you suspect that water has entered the fuel tank likely if the water was deep or if the ATV overturned Tow or trailer the ATV to your dealer for immediate service 1 Turn the fuel valve off 2 Drain water from the air box and change the air filter 1f equipped See page 112 3 Drain the fuel water from the carburetor for about 10 seconds 4 Remove the spark plug See page 127 132 MAINTENANCE AND LUBRICATION Vehicle Immersion AWARNING Fluids will be ejected through the spark plug hole and may cause serious injury to face or other body parts Stand clea
82. u stall or roll back wards follow the special procedure for braking described in this manual Always dis mount on the uphill side or to either side if the ATV is pointed straight uphill Turn the ATV around and remount following the procedure described in this manual Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as rocks or fallen trees Always follow proper procedures when operating over obstacles as described in this manual Always be careful of skidding or sliding On slippery surfaces like ice travel slowly and use extra caution to reduce the chance of skidding or sliding out of control 21 SAFETY Operator Safety Avoid operating the ATV through deep or fast flowing water If it s unavoidable travel slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Test the brakes after leaving water If necessary apply them lightly several times to allow friction to dry out the pads Always use the size and type of tires specified for your ATV and always maintain proper tire pressure Never modify an ATV through improper installation or use of accessories Never exceed the stated load capacity for your ATV FOR MORE INFORMATION ABOUT ATV SAFETY call the Consumer Product Safety Commission at 1 8
83. ur dealer for service if throttle problems arise Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation Always check the lever for free movement and return before starting the engine Also check occasionally during operation Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle lever 1 toward the handlebar The throttle lever is spring loaded Engine speed returns to idle and the ATV will slow down when the lever is released 56 FEATURES AND CONTROLS Electronic Throttle Control 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 AWARNING The Electronic Throttle Control ETC stops the engine in the event of a throttle system malfunction and is provided for your safety Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms Clutch Lever The clutch lever 1 is located on the left hand handlebar Squeeze the clutch lever toward the handlebar to disengage the clutch Disengage the clutch before shifting gears FEATURES AND CONTROLS Foot Brake Your Polaris ATV has a foot pedal 1 that activates the rear brakes I
84. uster A locknut 3 ei 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 Tighten the locknut and slide the boots over the cable adjuster until they touch at the midpoint of the adjuster 156 ADJUSTMENTS Handlebars If desired the handlebars can be adjusted for rider preference AWARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block bolts can cause limited steering or loosening of the handlebars which could result in loss of control and serious injury or death Follow the adjustment procedures exactly or see your Polaris dealer for service 1 Remove the instrument panel and locate the handlebar bolts 1 1 Loosen the four bolts and 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 ev left or right 3 Torque the front two bolts to 10 12 ft Ibs 14 17 Nm then torque the rear two bolts A gap of up to ew 1 8 will remain at the rear bolts 157 ADJUSTMENTS Carburetor Idle RPM If the engine idle speed is not satisfactory and all other conditions are favorable the carburetor can be adjusted 1 Warm up the engine by running the vehicle for five minutes or until operating temperature is reached 2 Apply the park brake and place the
85. ustomer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your ATV is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage 178 WARRANTY WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any ATV that has been altered structurally modified neglected improperly maintained used for racing or used for purposes other than for which it was manufactured or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts com ponents 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
86. ver back it down the hill One maneuver that can be used when it s necessary to turn around while climbing a hill is the K turn 1 Keep your body weight uphill 2 Pull in the clutch lever and apply the front and rear brakes 3 When completely stopped shut off the engine Leaving the transmission in gear release the clutch lever and lock the park brake 4 Dismount on the uphill side of the vehicle or on the left side if the vehicle is pointing straight uphill 82 OPERATION Driving Safely Turning Around on a Hill 5 Staying uphill of the ATV turn the handlebars full left Reach across the handlebar and apply the front brakes to unlock the park brake 6 With the front brakes applied pull in the clutch lever Use the brakes to slowly allow the vehicle to roll around to your right until it s pointing across the hill or slightly downward 7 With the front brakes still applied release the clutch lever and lock the park brake Remount from the uphill side keeping body weight uphill Uphill 8 Pull in the clutch lever shift into neutral and restart the engine 9 Release the park brake and slowly release the clutch lever allowing the ATV to proceed slowly Stay in first gear using the brakes for additional speed control if necessary until more level ground is reached Do not apply the brakes abruptly when driving downhill 83 OPERATION Driving Safely Driving Downhill Whenever descending a hill fol
87. with this ATV Never exceed the stated load capacity for this ATV 49 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Operating on frozen bodies of water WHAT CAN HAPPEN Severe injury or death can result if the ATV and or the operator fall through the ice HOW TO AVOID THE HAZARD Never operate the ATV on a frozen body of water 50 SAFETY Operator Safety AWARNING Operating a damaged ATV can result in an accident with serious injury or death After any overturn or accident have a qualified service dealer inspect the entire machine for possible damage including but not limited to brakes throttle and steering systems AWARNING 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 Exposure to the hot components could result in a fire Always keep combustible materials away from the exhaust system 51 FEATURES AND CONTROLS Engine Electrical Switches 52 FEATURES AND CONTROLS Engine Electrical Switches 1 Start Button The start button engages the starter Always release the start button as soon as the engine starts 2 Engine Stop Switch The purpose of this switch is to provide the operator with a quick means of engine shutdown in case of an emergency The engine will not

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