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Polaris MV700 User's Manual

1. 1 Disconnect the hold down strap holding the battery in position and remove battery cover Remove the battery vent tube Disconnect the black negative battery cable first Disconnect the red positive battery cable last Lift the battery out of the ATV Be careful not to tip the battery sideways which could spill electrolyte 4 CAUTION If electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle VLC Gb 98 MAINTENANCE Battery Battery Installation 1 Ensure that the battery is fully charged 2 Place the battery in the battery holder 3 Install the battery vent tube NOTE The vent tube must be free of obstructions and securely installed Route the tube away from the frame and vehicle body to prevent contact with electrolyte 4 WARNING Battery gases could accumulate in an improperly installed vent tube and cause an explosion resulting in serious injury or death Always ensure that the vent tube is free of obstructions and is securely installed as recommended Coat the terminals with dielectric grease or petroleum jelly Connect and tighten the red positive cable first Connect and tighten the black negative cable last Reinstall the battery cover Secure the hold down strap OS OY Mu Be Verify that cables are properly routed NOTE Cables should be safely tucked away at the front and rear of the battery 99 MAIN
2. 4 Boots The best footwear is a pair of sturdy over the calf boots with low heels 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 26 CONTROLS Electrical Switches WARNING Activating the override switch while the throttle is open can cause loss of control resulting in severe injury or death Do not activate the override switch while the throttle is open Mode Reverse Override Switch 1 This vehicle is equipped with a reverse speed limiter system To gain additional power while backing depress the override switch The override switch also allows activation of AWD in reverse if the AWD switch is on This switch is also used to toggle through the different modes of the rider information center See page 38 Engine Stop Switch 2 The engine will not start or run when the switch is in the OFF position a TJ Its purpose is to provide the operator with a A Al quick means of engine shutdown in case of an emergency 2 Ignition Switch Lever 3 To start the engine slide the stop switch to the center RUN position and turn the ignition switch lever clockwise past the ON position Release the lever when the engine starts NOTE Both the ignition switch and the emergency engine stop switch will shut off all electrical power to the vehicle including lights To stop the engine slide the stop sw
3. M700 ATV Owner s Manual for Maintenance and Safety Read this manual carefully It contains important safety information This is an adult vehicle only Operation is prohibited for those under 16 years of age n AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER USE NEVERCARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS Part No 9921217 Rev 01 e PRINTED IN THE USA lt gt POLARIS The Way Out n AWARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 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 e Snowmobiles All terrain vehicles A
4. ing technique outlined in this manual Avoid crossing the side of a steep hill when possible Always use proper procedures if you stall or roll backwards while climbing a hill To avoid stalling maintain a steady speed when climbing a hill If you stall or roll backwards follow the special pro cedure for braking described in this manual Always dismount on the uphill side or to either side if the ATV is pointed straight uphill Turn the ATV around and remount following the procedure de scribed in this manual Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as rocks or fallen trees Always follow proper procedures when operating over obstacles as described in this manual Always be careful of skidding or sliding On slippery surfaces like ice travel slowly and use extra caution to reduce the chance of skid ding or sliding out of control Avoid operating the ATV through deep or fast flowing water If it s unavoidable travel slowly balance your weight carefully avoid sud den movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes SAFETY Operator Safety Wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them lightly several times to allow friction to dry out the pads Always check for obstacles or people behind the ATV before operat i
5. allow the engine to cool before removing the pressure cap 76 MAINTENANCE Engine Cooling System Radiator Coolant Level 1 ON UA cB parcbo Remove the bolts securing the front rack See illustration Remove the rack Remove the pressure cap 1 Using a funnel slowly add coolant through the radiator filler neck Reinstall the pressure cap Reinstall the front rack NOTE Use of a non standard pressure cap will not allow the recovery system to function properly Contact your dealer for the correct replacement part MAINTENANCE Engine Cooling System Coolant Level The recovery bottle 1 is located on the left side of the machine To access the recovery bottle remove the left side panel as outlined on page 82 Maintain the coolant level between the minimum and maximum marks on the bottle when the fluid is cool Add coolant as needed Cooling System Operation The engine coolant level is controlled or maintained by the recovery system The recovery system components are the recovery bottle radiator filler neck radiator pressure cap and connecting hose As coolant operating temperature increases the expanding heated excess coolant is forced out of the radiator past the pressure cap and into the 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 n
6. and after use of the vehicle Hot components can cause serious burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system Use caution when traveling through tall grass especially dry grass 25 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 Wearing a helmet can prevent a severe head injury Whenever riding a Polaris vehicle always wear a helmet that meets or exceeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has granted approval The 051039 approval number and serial 0006 031 number will also be displayed on the label 2 Eye Protection Do not depend on eyeglasses or sunglasses for eye protection Whenever riding a Polaris vehicle always wear shatterproof goggles or use a shatterproof helmet face shield Polaris recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean 3 Gloves Off road style gloves with knuckle pads are the best for comfort and protection
7. approved helmet increases the risk of a icis severe head injury or UE death in the event of an accident Operating without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants 13 SAFETY Operator Safety 4 amp WARNING 14 POTENTIAL HAZARD Operating the ATV after consuming alcohol or drugs WHAT CAN HAPPEN Consumption of alcohol and or drugs could seriously affect operator judgment Reaction time may be slower and operator balance and perception could be affected Consuming alcohol and or drugs before or while operating an ATV could result in an accident causing severe injury or death HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while operating an ATV WARNING POTENTIAL HAZARD Operating the ATV at excessive speeds WHAT CAN HAPPEN Excessive speed increases the operator s chance of losing control of the ATV which can result in an accident HOW TO AVOID THE HAZARD Always operate the ATV at a speed that s proper for the terrain visibility and operating conditions and your experience SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Attempt
8. by this emissions warranty or the standard warranty is the responsibility of the owner including the parts labor and other costs associated with recommended maintenance The exclusive remedy for breach of this limited warranty shall be at the exclusive option of Polaris repair or replacement of any defective materials components or products THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CON TRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IM PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICU LAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply if it is inconsistent with the controlling state law This limited warranty excludes failures not caused by a defect in material or workman ship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or any engine that has been used in ra
9. contact your Polaris dealer for free replacement Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system Polishing the Vehicle This vehicle has a factory dulled finish Do not polish this vehicle 105 MAINTENANCE Cleaning and Storage Storage Tips CAUTION Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur Never start the engine during the storage period Clean the Exterior Make any necessary repairs and clean the vehicle as recommended See page 104 Stabilize the Fuel 1 Fill the fuel tank 2 Polaris Carbon Clean is a fuel stabilizer and fuel system dryer It cleans the fuel system the combustion chamber and the exhaust ports It also prevents bacterial growth and promotes better starting after the storage period NOTE Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust systems 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the fuel in the tank and carburetor 4 Turn the fuel valve off 5 Drain the carburetor bowl Oil and Filter Change the oil and filter See page 70 Air Filter Air Box 1 Inspect and clean or replace the pre cleaner and air filter 2 Clean the air box 3 Drain the sediment tube Bre
10. entering slippery areas Engage AWD before wheels begin to lose traction Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward CAUTION Severe damage to drive train may occur if the AWD is engaged while the wheels are spinning Always allow the rear wheels to stop spinning before engaging AWD or engage AWD before wheels begin to lose traction WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control accident and serious injury or death Never apply the brakes during a skid Do not operate on excessively slippery surfaces Always reduce speed and use additional caution 53 OPERATION Driving Uphill 25 Maximum Whenever traveling uphill follow these precautions 1 Drive straight uphill 2 Avoid steep hills 25 maximum 3 Keep both feet on the footrests 4 Shift your weight uphill 5 Proceed at a steady rate of speed and throttle opening 6 Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle 4 WARNING 54 Braking and handling are greatly affected when operating in hilly terrain Improper procedure could cause loss of control or overturn and result in serious injury or death Avoid climbing stee
11. lusus 26 Safety Training 6 Severe Use erras Seles nr 63 Side Panel Removal 82 Sidehilling ssse 55 Spark Arrestor 00 94 Spark Plug Inspection 90 91 Spark Plug Recommendations 90 Spark Plugs 00 90 91 Specifications 112 113 Starting the Engine 47 48 Steering Assembly 79 Stop Switch 0 00 0 0 0 27 0 C2 a 104 109 Storage Tips 106 108 Switches 0 5 Secs hte 27 Switch Light 00 29 T Tachometer 000 40 Taillight ieephenekee jS 89 Throttle Cable Freeplay 103 Throttle Lever 00 28 TIT6S c sey Sore E ORAS 83 84 Tires Run Flat 36 Toe Alignment sessse 79 Transmission Oil 74 Transporting the ATV 110 Trip Meter ccc cea mee 40 Troubleshooting 114 117 Turning Around ona Hill 57 V Vehicle Identification Numbers 5 Vehicle Immersion 92 W Matranty o see cepe pmt ni 118 121 Washing the Vehicle 104 Wheel Installation 84 Wheel Nut Torque Specifications 84 Wheel Removal 83 Winch Switch susue 27 Winches 2 re 36
12. or kilometers as well as hours of operation It also includes a reverse speed limiter function that limits the ATV s speed to approximately 7 9 mph Refer to page 27 for additional information PESLARIS 1 Rider Information Center Speedometer needle in addition to showing vehicle speed the needle flashes when a warning condition exists 3 Speedometer CAUTION High water pressure may damage ATV components Wash the ATV by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage the speedometer lens and other plastic surfaces Do not use alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens Immediately clean off any gasoline that splashes on the instrument cluster 38 FEATURES Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster All segments will light up for 2 5 seconds at start up NOTE Ifthe instrument cluster fails to illuminate a battery over voltage may have occurred and the instrument cluster may have shut off to protect the cluster s electrical system If this occurs take the ATV to your Polaris dealer for proper diagnosis 1 Gear Indicator This indicator displays gear shifter position H High Range L Low Range N Neutral R Reverse 2 8 P Park 2 AWD Indicator This indicator illuminates when the AWD switch is Sy C in the AW
13. remove the mudflap screws 3 Remove the footwell MAINTENANCE Tires Refer to the specifications section beginning on page 112 for recommended tire type size and pressure 4 amp WARNING Operating your ATV with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death Maintain proper tire pressure Always use original equipment size and type when replacing tires Make sure the wheels are installed properly Always replace tires when the tread depth measures 1 8 3 mm or less Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less See illustration Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations All service must be performed ens by your authorized Polaris dealer Wheel Removal 1 8 3 mm l Stop the engine 2 Place the transmission in PARK 3 Lock the parking brake 4 Loosen the wheel nuts slightly 2 Elevate the side of the vehicle by placing a suitable stand under the footrest frame Remove the wheel nuts n 9 Remove the wheel 83 MAINTENANCE Tires Wheel Installation 4 WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Always ensure that all nuts are torqued t
14. the right side of the demand drive unit The drain plug 2 is located on the bottom right side of the unit Maintain the fluid level at the bottom of the fill hole threads 3 Fluid Check 1 Position the vehicle on a level surface 2 Remove the fill plug Check the fluid level 3 Add the recommended demand drive fluid as needed to bring the level to the bottom of the fill hole threads 4 Reinstall the fill plug Torque to specification Fluid Change Position the vehicle on a level surface Remove the fill plug Place a drain pan under the demand drive unit Remove the drain plug Allow the fluid to drain completely Clean and reinstall the drain plug Torque to specification Add the recommended fluid Reinstall the fill plug Torque to specification Check for leaks Dispose of used fluid properly UO co vA Se Gur a 73 MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in M the Periodic Maintenance Chart le beginning on page 63 Maintain the transmission oil level at the bottom of the fill plug hole 1 Refer to the Gearcase Specifications Chart on page 72 for recommended lubricants capacities and torque specifications See page 111 for the part numbers of Polaris products The transmission oil fill plug 2 is located on the right side of the ATV behind the footwell The transmission drain plug 3 is located on the bott
15. trip meter mode Press and hold the mode button override button until the total changes to 0 NOTE In the Rider Information Center the trip meter display contains a decimal point but the odometer displays without a decimal point Hour Meter Mode This mode logs the total hours the engine has been in operation Tachometer Mode The engine RPM is displayed digitally NOTE Small fluctuations in the RPM from day to day may be normal because of changes in humidity temperature elevation and electrical loads 40 FEATURES Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when the gauge is in the diagnostic mode To exit the diagnostic mode turn the ignition switch off and on Any movement of the tires will also cause the gauge to exit the diagnostic mode To enter the diagnostics mode 1 2 3 4 Turn the ignition switch off and wait 10 seconds Lock the parking brake Place the transmission in neutral Hold the mode reverse override button and turn the ignition switch on Release the switch as soon as the display is activated Use the mode button to toggle through the diagnostic screens 41 FEATURES Instrument Cluster Rider Information Center Diagnostic Mode Battery Voltage Screen View this screen to check battery voltage level Tachometer Screen View the tachometer to check engine speed AWD Diagnostic Screen The gauge indicates whether or not curre
16. 2348 2871323 2871534 60 40 Coolant qt 111 SPECIFICATIONS MV700 weight not to exceed 400 Ibs 181 kg 112 Shift Type Gear Reduction Low Gear Reduction Reverse Gear Reduction High Drive Ratio Front Drive Ratio Final Tire Size Pressure Front Tire Size Pressure Rear Front Brake Rear Brake Parking Brake Front Suspension Rear Suspension Shock Adjustment Headlight Taillights Brake Light Instrument Cluster Jetting Chart AMBIENT Clutching Chart Altitude Meters 0 1800 Feet 0 6000 P 1800 3700 6000 12000 P TEMPERATURE Meters 0 1800 Feet 0 6000 1800 3700 6000 12000 Shift Drive Clutch Weight 20 54 Blue Green N 5631214 SPECIFICATIONS MV700 Side Lever H L N R P 7 49 1 5 11 1 3 05 1 3 82 1 3 10 1 25 x 8 12 5 psi 34 5 KPa 25 x 8 12 5 psi 34 5 KPa Single Control Hydraulic Disc Single Control Hydraulic Disc Hydraulic lock all wheel MacPherson Strut with 8 2 21 cm of travel Progressive Rate with 8 5 21 6 cm of travel Rear Spring Preload Adjust 2 Single Beam on Grill 27 w 8 26 w 26 9 w LCD Below 40 F Below 5 C 40 F and above 5 C and above 157 5 Driven Clutch Spring Spring 20 56 Blue Green White Yellow EBS 41 37 N 5631215 PN 7041157 PN 7041635 PN 5132751 White Yellow PN 7041635 EBS 41 37 PN 7041157 PN 5132751 EBS models require no helix spring adjust
17. 3 Do not overfill SAFE ADD 8 OZ NOTE Due to the dipstick entry angle into the 3 crankcase the oil level will read higher on the bottom side of the dipstick Always read the level on the upper surface 4 of the dipstick 5 After reinstalling the dipstick seat the lever lock 70 MAINTENANCE Oil and Filter Change Change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 63 Always install a new filter when changing the oil 1 2 3 Position the vehicle on a level surface Run the engine for two to three minutes until warm Stop the engine Clean the area around the drain plug Place a drain pan beneath engine crankcase and remove the drain plug CAUTION Hot oil can cause serious burns Do not allow hot oil to touch skin Allow the oil to drain completely Replace the sealing washer on the drain plug NOTE The sealing surfaces on drain plug and crankcase should be 10 11 12 13 14 15 16 clean and free of burrs nicks or scratches Reinstall the drain plug and torque to 20 ft lbs 27 Nm Place shop towels beneath the oil filter Using an oil filter wrench turn the filter counterclockwise to remove Using a clean dry cloth clean the filter sealing surface on the crankcase Lubricate the o ring on the new filter with a film of fresh engine oil Check to make sure the o ring is in good condition Install the
18. 7 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate Follow lubrication guidelines in the Maintenance Section of the service or owner s manual to completely grease and lubricate the entire vehicle with Polaris Premium All Season Grease Battery Storage See page 100 for storage and charging procedures Storage Area Covers Set the tire pressure and safely support the ATV with the tires slightly off the ground Be sure the storage area is well ventilated Cover the vehicle with a genuine Polaris cover NOTE Do not use plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation 108 MAINTENANCE Cleaning and Storage Chrome Wheel Care if equipped Proper maintenance will protect chrome wheels from corrosion preserve wheel life and ensure a like new appearance for many years NOTE Chrome wheels exposed to road salt or salt in the air in coastal areas are more susceptible to corrosion if not properly cleaned Clean chrome wheels more often if they re exposed to salt or other corrosive elements 1 Wash chrome wheels frequently Use a mild detergent Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodically Use an automotive grade chrome po
19. AZARD Avoid operating the ATV through deep or fast flowing water If it s unavoidable to enter water that exceeds the recommended maximum depth see page 58 travel slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Always test the brakes after leaving water If necessary apply them several times to let friction dry out the pads 4 amp WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires or operation of the ATV with improper or uneven tire pressure could cause loss of control or accident HOW TO AVOID THE HAZARD Always use the size and type of tires specified for the ATV Always maintain proper tire pressure as specified 23 SAFETY Operator Safety 4 amp WARNING 24 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 acco
20. Climbing hills improperly WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper NS 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 high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Traveling downhill improperly WHAT CAN HAPPEN Improperly descending a hill could cause loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner s manual NOTE A special technique is required when braking while traveling downhill See page 56 Always check the terrain carefully before descending a hill Shift your weight backward Never travel down a hill at high speed Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when possible 19 SAFETY Operator Safety 4 amp WARNING 20 POTENTIAL HAZARD Improperly crossing hi
21. D position 9 3 Engine Hour Display Indicator 1 Service Interval Diagnostic Mode Indicator 5 Low Battery and Over Voltage This warning usually indicates that the ATV is being operated at an RPM too low to keep the battery charged A low battery warning may also occur under normal operation if the machine is at idle and high electrical load lights cooling fan accessories is applied Drive at a higher RPM or recharge the battery to clear the warning 6 Odometer Tachometer Tripmeter Hour Meter 7 Fuel Gauge The segments of the fuel gauge indicate the level of fuel in the front tank only Since use of the rear tank is recommended for normal operation the rear tank may already be empty Refuel immediately if the last segment of the fuel gauge clears 8 Check Engine Warning Indicator The word HOT displays if the engine overheats Do not operate the ATV if this warning appears Serious engine damage could result 9 Mode Indicator B 39 FEATURES Instrument Cluster Rider Information Center Standard Modes Use the MODE button to toggle through the mode options The reverse override button is also the MODE button See page 27 NOTE The transmission cannot be in reverse when using this feature Odometer Mode The odometer records the miles traveled by the ATV Trip Meter Mode The trip meter records the miles traveled by the ATV on each trip if it s reset before each trip To reset the trip meter select the
22. 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 amp WARNING The Electronic Throttle Control ETC stops the engine in the event of a throttle system malfunction and is provided for your safety Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms 28 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 To operate the lights the ignition switch lever must be in the ON position and the stop switch must be in the RUN position 4 WARNING Operating the ATV on streets or roads especially in darkness could result in an accident and serious injury or death Your ATV is not equipped with highway approved lights It s designed for and must be used for off road use only Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness Brake Lever The front and rear brakes are applied by squeezing the brake lever 1 toward the handlebar The front and rear brakes are hydraulically activated disc type brakes that are activated by only one lever Always test brake lever travel and master cylinder fluid level before riding When squeezed the lever
23. ING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas 44 OPERATION Break In Period The break in period for your new Polaris ATV is the first ten hours of operation or the time it takes to use the first two full tanks of gasoline No single action on your part is as important as following the procedures for a proper break in Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components CAUTION Excessive heat build up during the first three hours of operation will damage close fitted engine parts Do not operate at full throttle or high speeds for extended periods during the first three hours of use Engine and Drivetrain Break in 1 Fill the fuel tanks with gasoline See page 33 2 Check the oil reservoir level on the dipstick See page 70 Add oil if necessary to maintain the level between the safe and add marks 3 Drive slowly at first Select an open area that allows room to familiarize yourself with vehicle operation and handling 4 Vary the throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 46 6 Pull only light loads 7 During the break in period change both the oil and the filte
24. RANTY Polaris Sales Inc 2100 Highway 55 Medina MN 55340 gives a SIX MONTH LIM ITED WARRANTY on all components of the Polaris All Terrain Vehicle ATV against defects in material or workmanship Polaris also gives a one year limited warranty on the final drive chain for failure due to defects This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transferable 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 No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE AL LOWED 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 118 WARRANTY WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limite
25. TENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more remove the battery from the vehicle ensure that it s fully charged and store it out of the sun in a cool dry place Check battery voltage each month during storage and recharge as needed to maintain a full charge NOTE Power plug leads may need to be bent down so that the battery cover can be installed NOTE Battery charge can be maintained by using a Polaris Battery Tender charger or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point Replenishing Battery Fluid A poorly maintained battery will deteriorate rapidly Check the battery fluid level often The fluid level should be kept between the upper and lower level marks 1 To refill use only distilled water Tap water contains minerals that are harmful to a battery 100 MAINTENANCE Camber and Caster The camber and caster are non adjustable Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster 1 either clockwise or counterclockwise to increase or decrease spring tension NOTE Accessory springs are available through your Polaris dealer Handlebars The handlebars can be adjusted for rider preference 4 amp WARNING Improper adjustment of the
26. TVs RANGER utility vehicles Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today Many years of experience have gone into the engineering design and development of your Polaris vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your service needs during and after the warranty period We also take great pride in our complete line of apparel parts and accessories available through our online store at www purepolaris com Have your accessories and clothing delivered right to your door POLARIS The Way Out Copyright 2006 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 publicatio
27. Weekly wet conditions A Brake pad wear Monthly 100 160 Inspect periodically Battery 20H Monthly 200 820 Check terminals clean test Pa eme e Monthly 250 400 Inspect level change yearly fluid Rear gearcase oil 25H Monthly 250 400 Inspect level change yearly Monthly 250 400 Inspect level change yearly Engine breather 25 H Monthly 250 400 Inspect clean if needed filter if equipped p Perform these procedures more often for vehicles subjected to severe use E Emission Related Service m Have an authorized Polaris dealer perform these services tube 65 MAINTENANCE Periodic Maintenance Chart Throttle Cable Maintenance Interval whichever comes first Calendar Miles Km 50H 500 800 Lubricate all fittings pivots cables etc 50H ETC Switch Choke cable General lubrication Carburetor float bowl 500 800 Drain bowl periodically and prior to storage 500 800 Inspect adjust lubricate replace if necessary 500 800 Inspect adjust lubricate replace if necessary Carburetor air 500 800 Inspect ducts for proper intake ducts sealing air leaks flange 500 800 Inspect adjust replace as needed 1000 1600 Inspect coolant strength seasonally pressure test system yearly Drive belt Cooling system Engine oil change 100 H Oil filter change 100 H Valve clearance 100 H 1000 1600 Perform a break in oil change at on
28. acle Not all obstacles are immediately visible Travel with caution in unfamiliar terrain 59 OPERATION Driving in Reverse Follow these precautions when operating in reverse 1 Always check for obstacles or people behind the vehicle 2 Always avoid backing downhill 3 Back slowly 4 Apply the brakes lightly for stopping 5 Avoid turning at sharp angles 6 Never open the throttle suddenly 4 amp WARNING Failure to use caution when operating in reverse can result in serious injury or death Before shifting into reverse always check for obstacles or people behind the vehicle When it s safe to proceed back slowly Do not use the override switch unless additional power is required for vehicle movement Use with caution Avoid backing on inclines and avoid turning at sharp angles NOTE Your Polaris ATV is equipped with a reverse speed limiter The override button should be used with caution as rearward vehicle speed is greatly increased Do not operate at wide open throttle Open the throttle just enough to maintain a desired speed CAUTION Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust resulting in engine popping and or engine damage 60 OPERATION Parking on an Incline 1 WP wh zem s Avoid parking on an incline if possible If it s unavoidable follow these precautions Stop the engine Place the transmission in PARK Lock th
29. advance the hours quickly NOTE If you scroll past the intended number press and hold the button until the hours cycle back to zero 5 When the desired setting is displayed wait until the wrench icon stops flashing The new service interval is now programmed Miles Kilometers toggle The display in the tripmeter and odometer can be changed to display either standard or metric units of measurement 1 Enter the diagnostic mode 2 Toggle to the screen that displays either kilometers KM or miles 3 Press and hold the mode button until the letters flash then press and release the button once When the display stops flashing the mode has been set 43 OPERATION Fuel Safety 4 amp WARNING Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always refuel with the engine stopped and outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the area where refuel ing is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Turn the fuel valve off whenever the ATV is stored or parked 4 amp WARN
30. at the process Take the vehicle to your dealer for service as soon as possible MAINTENANCE Battery Always keep battery terminals and connections free of corrosion If cleaning is necessary remove corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the terminals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into a conventional battery 4 amp WARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN 97 MAINTENANCE Battery 4 WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last Battery Removal
31. ather Filter Inspect and clean or replace the breather filter Recoil Housing Drain the recoil housing See page 93 106 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 63 Demand drive unit front gearcase Rear gearcase if equipped Transmission Brake fluid change every two years and any time the fluid looks dark or contaminated Coolant test strength fill Fog the Engine 1 2 3 Support the front end of the machine so the engine is level or tilted slightly rearward Remove the spark plug Pour 2 3 tablespoons 29 44 ml of Premium 4 Synthetic OW40 engine oil into the hole NOTE Use a section of small hose and a small plastic squeeze bottle filled with the pre measured amount of oil Reinstall the spark plug Torque to specification Apply dielectric grease to the inside of the spark plug cap Reinstall the cap Turn the engine over several times using the recoil starter Oil will be forced in and around the piston rings and ring lands coating the cylinder with a protective film of fresh oil Treat the fuel system with Polaris Carbon Clean See page 106 If Polaris fuel system additive is not used the fuel tank fuel lines and carburetor should be completely drained of gasoline To eliminate any fuel remaining in the carburetor run the engine until it stops 10
32. ator 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 flaky and white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetion adjustments Wet Fouled Spark Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended oil improper use of the choke or incorrect carburetion adjustments 91 MAINTENANCE Vehicle Immersion CAUTION If your vehicle becomes immersed major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine If it s impossible to take your ATV to a dealer before starting it follow the steps outlined below 1 2 DN ON ds pa SOOO 11 Move the ATV to dry land or at the very least to water below the footrests Check the air box for any water and dry it if water is present Filter replacement is required if water intrusion is evident Turn the fuel valve off Remove the spark plug Loosen the carburetor drain screw 1 Turn the engine over several times using the electric start Dry the spark plug and reinstall or rep
33. cing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of Polaris If you have any questions regarding your warranty rights and responsibilities you should contact the Polaris Warranty Department at 1 763 417 8650 123 MAINTENANCE RECORD 124 MAINTENANCE RECORD 125 MAINTENANCE RECORD 126 A Accessories 20 000 ee 103 Age Restrictions 6 Air Filter Service 85 All Wheel Drive sse 37 Automatic Transmission 34 Auxiliary Brake 81 AWD is in zzv ES OX Rex uen 37 B Battery er eL 97 100 Battery Fluid 100 Battery Installation 99 Battery Removal 98 Battery Storage 100 108 Belt Tife an sisi geek RES 34 Brake Fluid 30 32 Brake Lever s 29 Brake Auxiliary 32 Brakelight 0 00 89 Brakes acier miarana An 80 81 Break In Period 45 Breather Filter 85 C Camber and Caster 101 Carburetor 000 102 Choke cece dace ee a clea ees 33 Chrome Wheel Care 109 Cleaning csc 6 een ce eee 104 109 Clutching Chart 113 Cold Weather Operation 48 Coolant Level 04 78 Cooling System 76 78 Cooling Sys
34. creases reducing the amount of belt pinch On Polaris ATVs the approximate gear ratio difference between high and low range is 1 2 25 This difference in gearing affects the operation of the PVT especially at speeds less than 7 MPH 11 KPH due to the system s dependence on engine speed For example when operating at a ground speed of 3 MPH 5 KPH in low range the engine speed would be around 3000 RPM This is well above the engagement speed of 1200 1400 RPM However in high range at 3 MPH 5 KPH the engine would be running at only 1500 RPM Whenever operating this close to the engagement speed the engine may be running at a speed too low to provide the pinch needed to prevent belt slip Belt slip is responsible for creating the excessive heat that destroys belts and causes outer clutch covers to fail By switching to low range while operating at low ground speeds the air temperature in the clutch cover is reduced by almost 160 degrees Reducing the temperature inside the clutch cover extends the life of the PVT components belt cover etc When To Use Low Range and High Range Operating at speeds less than 7 MPH 11 km h Low Towing heavy loads Low Operating in rough terrain Swamps mountains etc Low Operating at speeds greater than 7 MPH 11 km h 95 MAINTENANCE PVT System 4 amp WARNING Failure to comply with the instructions in this warning can result in severe injury or death Do not modify an
35. d warranty excludes any failures that are not caused by a defect in ma terial 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 rac ing 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 unau thorized parts In addition this warranty does not cover physical damage to paint or fin ish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the ATV due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the ATV The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or com ponents or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI DENTAL 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 limi
36. ded whenever the cover is loosened or removed to ensure proper aaa operation Use Polaris DOT 4 brake fluid Do not overfill 80 MAINTENANCE Brakes 2 Check the brake system for fluid leaks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness 5 Check the security and surface condition of the disc NOTE Pads should be changed when worn to 3 64 1 mm Auxiliary Brake The auxiliary brake system is intended to be used as a backup for the main brake system Should the main system fail the rear brake can be activated by depressing the foot pedal on the inside of the right footrest The hydraulic auxiliary brake system requires no adjustment 3 64 1 mm NOTE Since this is a rear brake only it will not be as effective as the all wheel single lever system 81 MAINTENANCE Side Panel Removal 1 2 Remove the seat Grasp the rear of the side panel near the rear cab With a firm motion pull the panel outward to disengage the side panel from the grommet Pull the panel downward and rearward to remove it from the ATV Reinstall the side panel by reversing the removal procedure Footwell Removal 1 2 4 82 Remove the four screws 1 on the bottom of the footwell Use a flat screwdriver or sidecutters to remove the plastic rivets 2 securing the footwell to the fenders Use a phillips screwdriver and wrench to
37. e amount of compression during starting The decompressor senses when the engine is spinning fast enough to start and restores compression when running 1 Position the vehicle on a level surface 2 Lock the parking brake 3 Shift the transmission into neutral 4 Move the engine stop switch to RUN and the ignition switch lever to ON NOTE Ifthe engine is cold use the choke as outlined on page 47 5 Grasp the recoil starter rope handle 2 firmly and pull slowly so you can feel the engine strokes NOTE Every other stroke will be a compression stroke and will make the rope harder to pull When a compression stroke is found continue pulling the rope just until the engine rolls past the stroke then stop pulling immediately 6 Allow the recoil rope to rewind into the recoil assembly then pull the rope abruptly and forcefully to start the engine 7 Repeat steps 5 6 if necessary CAUTION Extending the recoil starter rope until it stops can cause damage to the recoil assembly Do not extend the starter rope so far that it stops If the starter rope handle is not seated properly water may enter the recoil housing and damage components Make sure the handle is fully seated on the recoil housing especially when traveling in wet areas 35 FEATURES Run Flat Tires This ATV is equipped with run flat tires which permit limited operation with a flat tire However ATV load capacity is reduced when tire air pres
38. e overheating or PVT or engine damage See your Polaris dealer for more information about jetting the ATV for conditions in your area NOTE Pilot screws are sealed with metal plugs and are serviceable only by Polaris dealers Carburetor Idle If the engine idle speed is not satisfactory and all other conditions are favorable the carburetor can be adjusted l Start the engine and allow it to warm up for approximately five minutes 2 Place the transmission in gear 3 Lock the parking brake 4 Turn the screw in clockwise to raise RPM Turn the screw out counterclockwise to lower RPM 102 MAINTENANCE Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar 1 Locate the throttle cable adjuster at the handlebar M 2 Squeeze the end of the rubber boot and slide it far enough to expose the end of the inline cable adjuster 3 Loosen the adjuster lock nut 4 Rotate the boot to turn the adjuster until 1 16 to 1 8 1 5 3 mm of freeplay is achieved at the thumb lever NOTE While adjusting freeplay be 1 sure to flip the throttle lever back and forth Gra D 5 Tighten the lock nut 3 2 6 Squeeze the end of the rubber boot and slide it over the cable adjuster to its original position Accessories Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights See your Polaris dealer 103 MAINTENANCE Cleaning and Storage See page 111 for
39. e month 1000 1600 Replace with oil change 1000 1600 Inspect adjust Fuel system filter 100 H 1000 1600 Check for leaks at tank cap lines fuel valve filter pump carburetor replace lines every two years Radiator 100 H 1000 1600 Inspect clean external if applicable surfaces Cooling hoses 100 H 1 1000 1600 Inspect for leaks if applicable pipe p Perform these procedures more often for vehicles subjected to severe use E Emission Related Service m Have an authorized Polaris dealer perform these services 3M 12M 12M 12M 2M 66 MAINTENANCE Periodic Maintenance Chart Maintenance Interval whichever comes first Calendar Miles Km H Spark plug 100 H 1000 1600 Inspect replace as needed Ignition Timing 100 H 1000 1600 Wiring 100 H 12M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc Clutches drive 100 H 12M 1000 1600 Inspect clean replace worn and driven parts Front wheel 100 H 12M 1000 1600 Inspect replace as needed bearings Brake fluid 200 H 2000 3200 Change every two years 300 8000 4800 Winch System Refer to the operator s guide provided by the winch manufacturer espe o Adustas needed Toe adjustment Inspect periodically adjust when parts are replaced Adjust as needed p Perform these procedures more often for vehicles subjected to severe use E Emission Re
40. e or are traveling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to per form the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of the destination country before you move Vehicles importation rules vary considerably from country to country You may be required to present docu mentation of your move to Polaris Industries in order to continue your warranty cover age You may also be required to obtain documentation from Polaris Industries in order to register your vehicle in your new country 121 WARRANTY Exported Vehicles How to Get Service If Purchased From A Private Party If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased all warranty coverage will be denied Notice If your vehicle is registered outside of the country where it was purc
41. e parking brake Always block the rear wheels on the downhill side Turn the fuel valve off 61 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine intake or exhaust components as doing so may affect compliance with U S A EPA noise control requirements 40 CFR 205 and local noise level requirements Operation on Public Lands in the U S A Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100 1C Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public lands in the U S A is regu lated by 43 CFR 8343 Violations are subject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov ecfr Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design including factory set fuel delivery and ignition The engine and related components must be maintained at Polaris specifications to achieve optimal performance Adjustment to engine idle is the only adjustment Polaris recommends that the operator perform Any other adjustments s
42. e vehicle Cargo weight should be evenly distributed 1 3 on the front rack and 2 3 on the rear rack and mounted as low as possible When operating over rough or hilly terrain reduce speed and cargo weight to maintain stable driving conditions Do not obstruct the headlight beam with cargo Use low forward gear when hauling or towing heavy cargo to extend belt life Refer to the specifications section beginning on page 112 for capacities Towing Loads Always attach a towed load to the hitch point If towing a load reduce rear rack cargo weight by the amount of tongue weight The combination of rear rack cargo weight and tongue weight must not exceed the rear rack capacity See page 112 Maximum Towing Capacities Towed Load Level Ground 1500 Ibs 681 kg Towed Load 15 Incline 850 Ibs 386 kg Vertical Hitch Weight 150 Ibs 68 1 kg 49 OPERATION Hauling Cargo A 50 WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability which can result in serious injury or death Always follow these precautions when hauling cargo REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO CARGO WEIGHT DISTRIBUTION should be 1 3 on the front rack and 2 3 on the rear rack When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions Carrying loads on one rack only increa
43. eakdown 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 Although Polaris Premium 4 is the only oil recommended for use in this engine use of any API certified SH oil is allowable as long as it s OW 40 Oil may need to be changed more frequently if Polaris Premium 4 is not used Follow the manufacturer s recommendations for ambient temperature operation CAUTION Mixing brands or using a non recommended oil may cause serious engine damage We recommend the use of Polaris Premium 4 synthetic Oil or another OW 40 API certified SH oil Never substitute or mix oil brands 69 MAINTENANCE Oil Check The dipstick oil fill 1 is located on the engine on the left side of the ATV Do not start the engine before the oil check NOTE A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase If the oil level is over the full safe mark change the oil immediately 1 Position the vehicle on a level surface 2 Remove the dipstick and wipe it dry with a clean cloth NOTE Lift the lever lock 2 to remove the dipstick 3 Reinstall the dipstick completely but do not lock it The dipstick must be completely seated 4 Remove the dipstick and check the oil level Maintain the oil level between the SAFE and ADD marks
44. eir eligible family members are entitled to take the ATV RiderCourse Contact ATV Enrollment Express at 800 887 2887 or visit www atvsafety org for information on enrollment in the ATV RiderCourses Never allow anyone under 16 years of age to operate this ATV Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safe ty training course Always avoid operating an ATV on paved surfaces including side walks driveways parking lots and streets Never operate an ATV on a public street road or highway including a dirt or gravel road Never operate an ATV without wearing an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots a long sleeved shirt or jacket and long pants Never consume alcohol or drugs before or while operating an 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 foot rests of the ATV during operation Always travel slowly and use extra caution when operating on unfa miliar terrai
45. el filter should be replaced by your dealer after every 100 hours of operation or annually Do not attempt to clean the fuel filter 33 CONTROLS Automatic Transmission Gear Selector The transmission gear selector 1 is located on the right side of the vehicle H High Gear L Low Gear N Neutral R Reverse P Park To shift into HIGH or PARK apply the auxiliary brake to activate the high park lock out mechanism When shifting out of HIGH or PARK it s not necessary to apply the brake CAUTION Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage To change gears stop the vehicle and with the engine idling move the lever to the desired gear Apply the auxiliary brake before shifting into HIGH or PARK Whenever the ATV is left unattended always place the transmission in PARK and lock the parking brake Belt Life To extend belt life use low forward gear in heavy pulling situations and when operating at less than seven miles per hour for extended periods of time UD zr I 34 FEATURES Recoil Starter If the battery has been drained or damaged and cannot start the engine use of the recoil starter 1 will allow vehicle operation until repairs can be made The recoil starter is located on the right side of the machine Polaris 4 cycle engines are equipped with automatic decompressors This makes recoil starting possible by reducing th
46. ency situations if single lever brakes become inoperable 56 OPERATION Turning Around on a Hill If the vehicle stalls while climbing a hill never back down the hill Use the K turn to turn around 1 Stop the vehicle and lock the parking brake while keeping body weight uphill 2 Leave the transmission in forward and stop the engine 3 Dismount on the uphill side of the vehicle or on the left if the vehicle is pointing straight uphill 4 Staying uphill of the vehicle turn the handlebars full left 5 While holding the service brake release the parking brake lock and slowly allow the vehicle to roll around to your right until it s pointing across the hill or slightly downward 6 Lock the parking brake Remount the vehicle from the uphill side keeping body weight uphill 7 Restart the engine with the transmission still in forward 8 Release the parking brake and proceed slowly controlling speed with the service brake until the vehicle is on more level ground 57 OPERATION Driving Through Water AQ Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests 1 Follow these procedures when operating through water 1 Determine water depths and current before crossing 2 Choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles 4 After crossing dry the brakes by applying light pressure t
47. er 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 ES operator and or passenger HOW TO AVOID THE HAZARD Never carry a passenger The purpose of the long seat is to allow the operator to shift position as needed during operation It is not intended for carrying passengers WARNING POTENTIAL HAZARD Operating an ATV on paved surfaces including sidewalks paths parking lots and driveways WHAT CAN HAPPEN ATV tires are designed for off road use Operating on paved surfaces may seriously affect the handling and control of the ATV and could result in loss of control accident and or injury HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement If it s unavoidable travel slowly and avoid sudden turns or stops SAFETY Operator Safety 4 amp 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 4 WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet eye protection and protective clothing WHAT CAN HAPPEN Operating an ATV without an
48. ew 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 78 MAINTENANCE Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts If loose nuts and bolts are found see your Polaris dealer for service before operating the vehicle Toe Alignment 4 WARNING Severe injury or death can result from improper toe alignment and adjustment Do not attempt to adjust tie rod alignment All tie rod adjustments should be performed by an authorized Polaris dealer Use the following procedure to check the toe alignment of the vehicle The recommended toe alignment is 1 8 to 1 4 3 6 mm toe out 1 Setthe handlebars in a straight ahead position ay 05 MI p eee a Ed NOTE The steering frog can S 5 be used as an indicator vr of whether the Wey gr S SOs handlebars are straight The frog should always point straight back from the steering post 2 Place stands 1 in front of the vehicle perpendicular to the rear tires See illustration 3 Tie an elastic string around the stands making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in front of the vehicle 2 4 Measure the distance from 1 the string to the rim at the front and rear
49. handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars resulting in loss of control and possible serious personal injury or death Follow the adjustment procedures exactly or see your Polaris dealer for service 1 Remove the upper headlight pod 2 Loosen the four bolts 1 3 Adjust the handlebar to the desired height Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right 4 Torque the front two bolts to 10 12 ft Ibs 14 17 Nm then torque the rear two bolts A gap of up to 1 8 3 mm will remain at the rear bolts 101 MAINTENANCE Carburetor Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6 000 feet 1800 m and temperatures of 40 degrees F 4 degrees C or higher Above 6000 feet 1800 m the engine air fuel mixture becomes overly rich and the engine loses approximately 3 of its power for each 1000 foot 304 8 m increase in elevation Although this power cannot be regained adjustments to the carburetor and drive system can be made to allow more efficient operation Optional jets available from your Polaris dealer are required for operation above 6 000 feet and temperatures below 40 degrees F 4 degrees C NOTE Continuous operation of the engine without proper jetting when required can cause poor performanc
50. hased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ranty or service bulletin coverage of any kind Vehicles registered to Government offi cials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions call Polaris Customer Assistance United States 1 763 417 8650 Canada 1 204 925 7100 122 WARRANTY U S A EPA Emissions Limited Warranty This All Terrain Vehicle ATV or Off Road Utility Vehicle ORUV emissions limited warranty is in addition to the Polaris standard limited warranty for this vehicle Polaris warrants that this vehicle is 1 designed built and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and 2 free from defects in materials and workmanship that may keep it from meeting these requirements The emissions warranty period for this vehicle begins on the date the vehicle is delivered to the original retail purchaser and ends 30 months 2 5 years after that date or after 5000 km 3100 miles whichever comes first This emission related warranty covers components whose failure would increase an engine s emissions including electronic controls fuel injection exhaust gas recircula tion aftertreatment or any other system utilized in this vehicle to control emissions Re placing or repairing other components not covered
51. hould be performed by an authorized Polaris dealer The emissions label is located on the air box Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 This vehicle complies with European directives 97 24 EC and 89 336 EEC 62 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest most reliable condition Inspection adjustment and lubrication of important components are explained in the periodic maintenance chart Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use genuine Polaris parts available from your Polaris dealer NOTE Service and adjustments are important for proper vehicle operation If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oi
52. in 2 wheel drive at all times When the switch is on the ATV is in AWD and the AWD indicator light in the instrument cluster will be on When in AWD the demand drive unit will automatically engage any time the rear wheels lose traction When the rear wheels regain traction the demand drive unit will automatically disengage NOTE The override switch allows activation of AWD in reverse if the AWD switch is on See page 27 There is no limit to the length of time the vehicle may remain in AWD Engaging All Wheel Drive AWD The AWD switch may be turned on or off while the vehicle is moving Initially the vehicle s electronic system will not enable the AWD until the engine RPM is below 3100 Once enabled the AWD remains enabled until the AWD switch is turned off If the switch is turned off while the demand drive unit is moving it will not disengage until the rear wheels regain traction Engage the AWD switch before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to AWD CAUTION Switching to AWD while the rear wheels are spinning may cause severe drive shaft and gearcase damage Always switch to AWD while the rear wheels have traction or are at rest 37 FEATURES Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel The instrument cluster measures distance in miles
53. ing stunts increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt wheelies jumps or other stunts Avoid exhibition driving 4 WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV before 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 15 SAFETY Operator Safety 4 amp WARNING 16 POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation WHAT CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV If the operator s foot is not firmly planted on the footrest it could come into contact with the rear wheels and lead to accident or injury HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation WARNING POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn HOW TO AVOID THE HAZARD Travel slo
54. install the fill plug Torque to specification Oil Change 1 Place a drain pan beneath the drain and remove the drain plug Catch and discard used oil properly 2 Clean and reinstall the drain plug with a new sealing washer Torque to specification 3 Remove the side fill plug and add the recommended fluid 4 Check the oil level Maintain the oil level at the bottom of the fill plug hole 5 Reinstall the fill plug Torque to specification 6 Check for leaks 75 MAINTENANCE Engine Cooling System To ensure that the coolant maintains its ability to protect the engine Polaris recommends that you drain the system completely 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 Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water See page 111 for the part numbers of Polaris products NOTE Always follow the manufacturer s mixing recommendations for the freeze protection required in your area Any time the cooling system has been drained for maintenance or repair replace the coolant If the recovery bottle has run dry the level in the radiator should be inspected Add coolant as needed 4 amp WARNING Escaping steam can cause severe burns Never remove the pressure cap while the engine is warm or hot Always
55. itch either right or left to the OFF position Infrared Light Switch 4 Use this switch to activate the infrared lights if equipped When the infrared lights are turned on all other lights on the vehicle are turned off Front Rear Winch Switch 5 Use the switch on the pod to select either the front or rear winch Winch Operation Switch 6 After selecting either the front or rear winch with the switch on the pod use the handlebar switch to operate the winch Operation instructions can be found in the winch operation guide provided by the winch manufacturer 27 CONTROLS 4 WARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death Never start or operate an ATV with a sticking or improperly operating throttle Always contact your dealer for service if throttle problems arise Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation Always check the lever for free movement and return before starting the engine Also check occasionally during operation Throttle Lever Engine speed and vehicle movement are controlled by REA pressing the throttle lever 1 The LH Jj throttle lever is spring loaded ZA Engine speed returns to idle when P ep the lever is released ws A This ATV is equipped with Polaris 1 Electronic Throttle Control
56. l sump or crankcase Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer 63 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key p Perform these procedures more frequently for vehicles subjected to severe use E Emission Control System Service California m Have an authorized Polaris dealer perform these services 4 amp WARNING Improperly performing the procedures marked with a m could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services 64 MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first Maintenance Interval whichever comes first Calendar Miles Km fase Varese a reed Front Pre Rid ed See Pre Ride Checklist gt Fron suspension eee 50 po gt Fear susparsion _ Prere me p rem D Brake fluid level Pre Ride D Brake lever travel Pre Ride psesmem Fe8e Wheels fasteners Pre Ride Ferers Pen g Air filter pre filter HJER Inspect clean often Check level daily change coolant every 2 years Check operation Inspect replace as needed E su Headlamp tail lamp Air filter Daily Weekly main element Drain water as needed check often if operating in Recoil housing
57. lace it with a new plug Tighten the carburetor drain screw Turn the fuel valve on Attempt to start the engine If necessary repeat the drying procedure Take the ATV to your dealer for service as soon as possible whether you succeed in starting it or not NOTE f water has been ingested into the PVT follow the procedure 92 on page 96 for drying out the PVT MAINTENANCE Recoil Housing Always drain the recoil housing 1 after operating the vehicle in wet conditions Drain the housing before storing the vehicle NOTE Make sure the housing is completely dry before reinstalling the drain screw NOTE Water will enter the recoil housing if the starter handle is disengaged from the rope guide when under water Stop the engine Place the transmission in gear Lock the parking brake Remove the drain screw on the bottom of the recoil housing Reinstall the drain screw UI cS ake ole ae NOTE Do not open the crankcase drain unless the engine has ingested water On 4 cycle engines some engine oil will be lost if the crankcase drain is opened 93 MAINTENANCE Spark Arrestor 4 amp WARNING 10 94 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 Rem
58. lated Service m Have an authorized Polaris dealer perform these services Headlight aim 67 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 63 Items not listed in the chart should be lubricated at the General Lubrication interval e ue p e Engine Oil Polaris Premium 4 Synthetic Add to proper level on dip ow40 stick Brake Fluid DOT 4 Only Maintain level between fill lines See page 30 Transmission Oil Polaris AGL Synthetic See page 74 Gearcase Lube Demand Drive Fluid Demand Drive LT Premium Fluid See page 73 Front Gearcase Rear Gearcase Oil Premium ATV Angle Drive Fluid See page 75 General Lubrication Polaris Premium All Season Grease Front Prop Shaft Yoke Polaris Premium U Joint Lube Grease fittings 3 pumps Fig 1 maximum every 500 miles before long periods of stor age or after pressure wash ing or submerging 68 MAINTENANCE Premium 4 Synthetic Lubricant Polaris Premium 4 All Season synthetic engine oil has been specially formulated for use in Polaris 4 cycle engines It s a fully synthetic high performance multi viscosity oil designed to provide the ultimate in lubrication performance and protection See page 111 for the part numbers of Polaris products Premium 4 possesses unsurpassed film strength over the widest possible temperature range It resists viscosity and frictional br
59. lish 4 Routinely and liberally apply a weather resistant wax to each polished chrome wheel Choose a product suitable for chrome finishes Read and follow the product labels and instructions Removing Corrosion If light rust is found on the chrome finish use steel wool 0000 OTT grade to remove it Gently rub the affected areas with the steel wool until the corrosion has been removed Clean and polish the wheel as outlined above 109 MAINTENANCE Transporting the ATV Follow these procedures when transporting the vehicle 1 Stop the engine 2 Place the transmission in PARK and lock the parking brake 3 Turn the fuel valve off Make sure the fuel caps oil cap and seat are installed securely 4 Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets 110 POLARIS PRODUCTS Part No Description Engine Lubricant 2870791 Fogging Oil 12 oz Aerosol 2871281 Premium 4 Synthetic OW 40 4 Cycle Engine Oil qt 2871844 Premium 4 Synthetic OW 40 4 Cycle Engine Oil gal Gearcase Transmission Lubricants 2873602 Premium AGL Synthetic Gearcase Lubricant qt gal 2873603 2871653 2872276 2870465 2876251 Demand Drive LT Premium Fluid 8 oz 2871312 2871322 2871423 2871460 2871515 2871557 2871329 2872073 287
60. lls and turning on hills WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of control or overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 57 Use extra caution when turning on any hill Avoid crossing the side of a steep hill When crossing the side of a hill Always follow proper procedures as described in the owner s manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Stalling rolling backwards or improperly dismounting while climbing a hill WHAT CAN HAPPEN The vehicle could overturn HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill If all forward speed is lost Keep your weight uphill Apply the single lever brake gradually When fully stopped apply the auxiliary rear brake as well then lock the parking brake If the ATV begins rolling backwards Keep weight uphill Never apply engine power Never apply the auxiliary rear brake while rolling backwards Apply the single lever brake gradually When fully stopped apply the auxiliary rear brake as well and then lock the parking brake Dismount on uphill side or to either side if ATV is pointed straight uphill Turn the ATV around and re
61. ment 113 TROUBLESHOOTING Drive Belt and Cover Problems Driving the ATV onto a Shift transmission to low range during loading of the ATV pickup or tall trailer in to prevent belt burning high range Starting out going up a When starting out on an incline use low range or dis steep incline mount the ATV after first applying the park brake and perform the K turn as described on page 57 Driving at low RPM or Drive at a higher speed or use low range more frequently low ground speed at The use of low range is highly recommended for cooler approximately 3 7 MPH PVT operating temperatures and longer component life Insufficient warm up of Warm the engine at least 5 minutes With the transmission ATVs exposed to low am in neutral advance the throttle to about 1 8 throttle in bient temperatures short bursts 5 to 7 times The belt will become more flex ible and prevent belt burning Slow and easy clutch en Use the throttle quickly and effectively for efficient enga gagement gement Towing pushing at low Use low range only RPM low ground speed Utility use plowing snow Use low range only dirt etc Stuck in mud or snow Shift the transmission to low range and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing overlarge ob Shift the transmission to low range and carefully use fast jects from a stop
62. mount following the procedure described in the owner s manual See page 57 21 SAFETY Operator Safety 4 amp WARNING 22 POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Avoid operating over large obstacles such as rocks and fallen trees when possible If unavoidable use extreme caution and always follow proper procedures as outlined in the owner s manual 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 WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN The ATV could collide with an obstacle or person resulting in severe injury HOW TO AVOID THE HAZARD Before shifting into reverse gear always check for obstacles or people behind the ATV When it s safe to proceed back slowly SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Operating the ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident or overturn HOW TO AVOID THE H
63. n Be alert to changing terrain conditions Never operate on excessively rough slippery or loose terrain Always follow proper turning procedures as described in this manu al Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speeds SAFETY Operator Safety Always have the ATV inspected by an authorized Polaris dealer if it s been involved in an accident Never operate on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills Check the ter rain carefully before ascend a hill Never climb hills with excessive ly slippery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes Never go over the top of a hill at high speed Always follow proper procedures for going downhill and for braking on hills Check the terrain carefully before you start down a hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when pos sible Always follow proper procedures for crossing the side of a hill Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV Never attempt to turn the ATV around on any hill until you ve mastered on level ground the turn
64. n 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 2007 MV700 Owner s Manual P N 9921217 2 TABLE OF CONTENTS VEHICLE IDENTIFICATION NUMBERS 5 SAFETY 14er tha oeste Desde ed 6 CONTROLS iioii erri teria S 27 FEATURES i qoi qae ves que ced uet Neid qs 35 OPERATION uus cane onna nR ADEO 44 EMISSION CONTROL SYSTEMS 62 MAINTENANCE 29 1399 bendut eres 63 POLARIS PRODUCTS ouaaa 111 SPECIFICATIONS s s22 06 525 RR XE nues ERES 112 TROUBLESHOOTING 4 1 eek en tae ERE 114 WARRANTY S ica preni attacca gla E 118 MAINTENANCE RECORD 124 INDEX 2x carni 2 hou ho e ER to eta ee oe in 127 VEHICLE IDENTIFICATION NUMBERS Record your vehicle s identification numbers in the spaces provided Vehicle Model Number Frame VIN 1 Engine Serial Number 2 SAFETY Operator Safety 4 amp WARNING Failure to follow the warnings contained in this manual can result in serious injury or death A Polaris ATV is not a toy and can be hazardous to operate This vehicle handles differently than other vehicles such as motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or
65. n brake system if the main system becomes inoperative If the rear wheels slide while using the auxiliary brake reduce brake pedal pressure to brake the rear wheels without skidding Brake Fluid Level Check the brake fluid level frequently for the auxiliary brake system The reservoir is located under the seat or near the auxiliary brake Maintain the fluid level between the maximum and minimum marks 32 CONTROLS Choke The choke assists in starting a cold engine Refer to the engine starting procedure on page 47 for correct choke and throttle settings during starting Fuel Requirements Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Fuel Valve The fuel valve 1 is located on the REAR left side panel TANK OFF Turn the fuel valve off for vehicle storage and when transporting ORE REAR TANK We recommend using the rear tank fuel supply first Switch to the front tank when the rear tank is empty It will be easier to monitor remaining fuel at the front tank gauge FRONT TANK Use the front tank fuel supply when the rear tank is empty NOTE There is no reserve fuel supply on this vehicle When both fuel tanks are empty the vehicle will not operate Fuel Tanks The front fuel tank filler cap 2 is located directly below the handlebar The rear fuel tank and filler cap 3 are located behind the seat under the rear rack Fuel Filter The in line fu
66. n the engine and air box Remove the clamps and pull the filter out of the hoses NOTE It s not necessary to remove the lower hose from the engine 3 4 5 Inspect the filter for debris Blow gently through the filter in the direction of the arrow to check for clogging Replace if needed Check the hoses for cracks deterioration abrasion or leaks Replace as needed Reinstall the filter and secure the clamps NOTE The filter is effective with the arrow pointing in either direction CAUTION Operation of your vehicle without a breather filter can cause engine damage Always reinstall the breather filter after removing for service 85 MAINTENANCE Lights When servicing a halogen lamp don t touch the lamp with bare fingers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp 4 amp WARNING Poor lighting while driving can result in severe injury or death Headlight and taillight lenses become dirty during normal operation Wash the headlights frequently to maintain lighting quality Hot components can cause serious burns to skin Allow lamps to cool before servicing Headlight Lamp Replacement 1 2 3 4 2x 6 7 Remove the two screws on the lower front corners of the headlight pod Remove the screw from the rear of the pod Lift the pod slightly while depressing the tabs at the rear of the pod Lift the pod cover and disconnect the
67. new filter and turn by hand until the filter gasket contacts the sealing surface then turn and additional 1 2 turn Remove the dipstick and fill the sump with two quarts 1 9 1 of recommended oil Place the gear selector in PARK and set the parking brake Start the engine and let it idle for one to two minutes Stop the engine and inspect for leaks Re check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick Dispose of used filter and oil properly 71 MAINTENANCE Gearcase Specification Chart Gearcase Lubricant Capacity Fill Plug Drain Torque Plug Torque Main Bu 15 2 oz 14 ft Ibs 14 ft Ibs Gearcase 450 ml 19 Nm 19 Nm Transmission Bine Gearcase Lube Demand Drive 9 oz 11 ft Ibs Unit Front i 265 ml 15 Nm Gearcase i Rear Premium 10 oz Side plug 14 ft Ibs Gearcase ATV Angle 300 ml 16 ft Ibs 19 Nm Drive Fluid 22 Nm 72 MAINTENANCE Front Gearcase Demand Drive Fluid Always check and change the demand drive fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 66 We recommend the use of Demand Drive LT Premium Fluid Use of other fluids may result in improper operation of components Refer to the Gearcase Specifications Chart on page 72 for recommended lubricants capacities and torque specifications See page 111 for the part numbers of Polaris products The fill plug 1 is located on
68. nfrared Light Switch 27 Instrument Cluster 38 43 J Jetting Chart 008 113 K K T tnilel vvv ee Sick te 57 127 INDEX L Light Switches 29 Tights ey eetere koran eesi 86 89 Locking the Parking Brake 31 Low Beam Adjustment 88 Low Range 00 95 Lower Headlamp 89 Lubrication Guide 68 M Maintenance Chart 63 67 Maintenance Record 124 126 Making Turns 52 Master Cylinder 30 Mode Reverse Override Switch 27 N Noise Emission Control System 62 Oo Odometer eeess 40 Oil Change sesesess 71 OilCheck toes eeu e pene 70 Oil Filter Change 71 Operator Safety 6 25 P Parking Brake 31 Parking on an Incline 61 Periodic Maintenance Chart 63 67 Polaris Products 111 Pre Ride Inspection 46 Premium 4 Synthetic Lubricant 69 PVT Break in 45 PVT Drying esee 96 PVT System esses 95 96 R Radiator Coolant Level 77 Rear Gearcase Oil 75 Rear Spring 00 101 Recoil Housing 93 Recoil Starter 35 Reverse Override Switch 27 Rider Information Center 39 43 Run Flat Tires 36 128 S Safe Riding Gear
69. ng in reverse When it s safe to proceed in reverse move slowly and avoid turning at sharp angles Always use the size and type of tires specified for your ATV and always maintain proper tire pressure Never modify an ATV through improper installation or use of acces sories Never exceed the stated load capacity for your ATV Cargo must be properly distributed and securely attached Reduce speed and follow the instructions in this manual for carrying cargo or towing Allow a greater distance for braking FOR MORE INFORMATION ABOUT ATV SAFETY call the Consumer Product Safety Commission at 1 800 638 2772 or visit www cpsc gov visit www atvsafety org or call Polaris at 1 800 342 3764 Equipment Modifications We are concerned for the safety of our customers and for the general public Therefore we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury The warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power NOTE The addition of certain accessories including but not limited to mowers blades tires sprayers or large racks ma
70. ng in severe injury or death Never run an engine in an enclosed area 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Lock the parking brake NOTE The starter interlock will prevent the engine from starting if the transmission is in gear and the brake is not engaged 4 Turn the fuel valve on 5 Sit on the vehicle NOTE Do not use the choke if starting a warm engine Excessive use of the choke can cause the spark plug to become wet fouled 6 Ifthe engine is cold pull the choke knob 1 out until it stops 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 NOTE Ifthe knob doesn t stay where positioned increase the tension by rotating the tension adjusting nut clockwise 7 Move the engine stop switch to RUN NOTE Do not press the throttle while starting the engine 47 OPERATION Starting the Engine 8 Turn the ignition lever past the ON position to engage the starter Activate the starter for a maximum of five seconds releasing the lever when the vehicle starts 9 Ifthe engine does not start return the ignition lever to the OFF position and wait five seconds Activate the star
71. nt is flowing through the AWD coil only on models with switchable AWD This screen is for informational purposes only Please see your dealer for all major repairs Gear Circuit Diagnostic Screen This screen displays the resistance value in ohms being read at the gear switch input of the gauge This screen is for informational purposes only Please see your dealer for all major repairs Programmable service interval When the hours of engine operation equal the programmed service interval setting the wrench icon will flash for 5 seconds each time the engine is started When this feature is enabled it provides a convenient reminder to perform routine maintenance See page 43 NOTE The service interval is programmed at 50 hours at the factory 42 FEATURES Instrument Cluster Rider Information Center Diagnostic Mode Programmable service interval To enable or disable the service interval 1 Enter the diagnostic mode 2 Toggle to the service interval screen 3 Press and hold the mode button for about 7 seconds until either ON or OFF appears in the Rider Information Center depending on your preference To reset the service interval 1 Enter the diagnostic mode 2 Toggle to the service interval screen 3 Press and hold the mode button for 2 3 seconds until the wrench icon flashes Release the button 4 Press and release the mode button once to advance the setting by one hour Press and hold the mode button to
72. o specification Do not service axle nuts that have a cotter pin installed See your Polaris dealer 1 Place the transmission in PARK Lock the parking brake 3 Place the wheel on the wheel hub with the valve stem toward the outside and the rotation arrows on the tire pointing toward forward rotation 4 Install the wheel nuts and finger tighten them 5 Lower the vehicle to the ground 6 Torque the wheel nuts to specification 90 ft Ibs 122 Nm 27 ft Ibs 37 Nm Cast Aluminum Steel Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loosened for maintenance service tem Speciation J 2 Piece Flange Nut 27 ft lbs 37 Nm 84 MAINTENANCE Air Filter Service 1 3 6 Remove the seat release the 1 air box cover clips and 2 remove the air box cover Loosen the clamp and remove the filter Remove the fabric type pre filter 1 from the main filter 2 Wash the pre filter in soapy water then rinse and let dry Reinstall the pre filter over the main filter Replace the main filter if needed Reinstall the filter into the air box and tighten the clamp Do not over tighten the clamp as filter damage could occur Reinstall the air box cover and the seat Breather Filter Hose 1 2 To access the breather filter 3 remove the left side panel as outlined on page 82 The breather filter is on the hose that runs betwee
73. o 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 63 The following areas need special attention engine oil transmission oil demand drive fluid rear gearcase oil and all grease fittings 4 CAUTION Major engine damage can result if the vehicle is not thoroughly inspected after operation in water Perform the services outlined in the maintenance chart If your vehicle becomes immersed or is operated in water that exceeds the footrest level take it to your dealer for service before starting the engine 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 92 Have the vehicle serviced by your dealer at the first opportunity 58 OPERATION Driving Over Obstacles Be alert Look ahead and learn to read the terrain you re traveling on Be constantly alert for hazards such as logs rocks and low hanging branches 4 amp WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obst
74. of the front rim 3 Rear measurement should be 1 16 1 8 1 5 3 mm more than the front measurement MET NOTE f you discover improper alignment see your Polaris dealer for service 79 MAINTENANCE Brakes The front and rear brakes are hydraulic disc brakes activated by moving the single brake lever toward the handlebar These brakes are self adjusting The following checks are recommended to keep the brake system in good operating condition Check more often if brakes are used heavily under normal operation 4 amp WARNING Never store or use a partial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of accident or severe injury After opening a bottle of brake fluid always discard any unused portion 1 Always keep brake fluid at an adequate level see page 30 4 amp WARNING An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill NOTE Under normal operation the 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 nee
75. om left hand side of the gearcase Cil Check 1 Remove the footwell see page 82 2 Remove the fill plug and check the oil level 3 Reinstall the fill plug Torque to specification 4 Reinstall the footwell Oil Change 1 Remove the footwell see page 82 2 Remove the drain plug and drain the oil into a drain pan Dispose of properly Clean and reinstall the drain plug Torque to specification Remove the fill plug and add the recommended fluid Reinstall the fill plug Torque to specification Check for leaks Reinstall the footwell PA OY UB Ga 74 MAINTENANCE Rear Gearcase Oil The rear gearcase has two fill plugs The rear fill plug is located on the rear of the gearcase and is not c O easily accessible The side PA fill plug 1 is located on the DA left side of the gearcase Use the side fill plug when checking or changing oil Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 63 Maintain the oil level 2 even with the bottom of the side fill hole Refer to the Gearcase Specifications Chart on page 72 for recommended lubricants capacities and torque specifications See page 111 for the part numbers of Polaris products Oil Check 1 Position the vehicle on a level surface 2 Remove the side fill plug and view the oil level through the fill plug hole 3 Add the recommended gearcase oil as needed 4 Re
76. ove any combustible materials from the area Wear eye protection and leather work gloves Do not stand behind or in front of the vehicle while purging Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas Never go under the vehicle while it s inclined Remove the arrestor clean out plug 1 from the bottom of the muffler Place the transmission in PARK Start the engine Quickly squeeze and release the throttle lever several times to purge carbon from the system If carbon comes out of the exhaust cover or plug the exhaust outlet Wear protective gloves Lightly tap on the exhaust pipe with a rubber mallet while repeating step 4 If particles are still suspected to be in the muffler elevate the rear of the vehicle one foot 30 cm higher than the front Block the wheels Place the transmission in PARK Lock the parking brake Repeat steps 4 6 until no more particles are expelled Stop the engine Allow the arrestor to cool Reinstall the arrestor plug and remove the exhaust outlet cover or plug MAINTENANCE PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements As engine speed increases the force exerted on the movable drive sheave by the flyweights also increases This in turn increases the amount of pinch applied to the drive belt Similarly if the engine speed decreases the amount of centrifugal force de
77. over obstacles if you fail to take proper precautions Read and understand your owner s manual and all warnings before operating a Polaris ATV Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age Know Your Vehicle As the operator of the vehicle you are responsible for your personal safety the safety of others and the protection of our environment Read and understand your owner s manual which includes valuable information about all aspects of your vehicle including safe operating procedures Safety Training ATV safety training is a top priority for Polaris When you purchased your new ATV your dealer instructed you on the authorized ATV RiderCourse available to you and your eligible family members This training is included in the purchase price of your ATV Polaris strongly encourages you and your eligible family members who will be riding the ATV to take the ATV RiderCourse You were also provided with printed materials that explain safe operating procedures You should review this information on a regular basis If you purchased a used Polaris ATV you can take the ATV RiderCourse by calling ATV Enrollment Express at 800 887 2887 or by visiting www atvsafety org Purchasers of a used Polaris ATV will be charged for this training A Polaris ATV is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this
78. p hills 25 maximum Use extreme caution when operating on hills and follow proper operating procedures outlined in the owner s manual OPERATION Driving on a Hillside Sidehilling 4 amp WARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn resulting in severe injury or death Avoid crossing the side of a hill when possible Follow proper procedures as outlined in the owner s manual Sidehilling can be dangerous and should be avoided if at all possible If you encounter a situation where sidehilling is necessary follow these precautions 1 Slow down 2 Shift your weight uphill 3 Keep your feet on the footrests 4 Steer slightly into the hill to maintain vehicle direction NOTE Ifthe vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately 55 OPERATION Driving Downhill WARNING Excessive speed when traveling downhill can cause loss of control and serious injury or death Slow down Applying the brakes too firmly may cause the rear wheels to lock which could result in loss of control and serious injury or death Apply the brakes gradually When driving downhill follow these precautions 1 Shift your weight uphill 2 Drive straight downhill 3 Slow down 4 Squeeze the brake lever gradually NOTE Before operating your ATV learn how to use the auxiliary brake for emerg
79. ped posi brief aggressive throttle application to engage clutch tion WARNING Excessive throttle may cause loss of control and vehicle overturn Belt slippage from water Shift the transmission to neutral Using the throttle vary or snow ingestion into the the engine RPM from idle to full throttle Repeat several PVT system times as required During this procedure the throttle should not be held at the full position for more than 10 seconds Clutch seals should be inspected for damage if repeated leaking occurs Clutch malfunction Contact your Polaris dealer for inspection of clutch com ponents Poor engine performance Check for fouled plugs or foreign material in gas tank fuel lines or carburetor Contact your dealer for service 114 TROUBLESHOOTING Contact your Polaris dealer for service if you re unable to identify solutions using the following charts Engine Doesn t Turn Over Possible Cause Solution Tripped circuit breaker Reset the breaker Low battery voltage Recharge battery to 12 5 VDC Loose solenoid connections Check all connections and tighten Engine Turns Over Fails to Start Possible Cause Solution Crankcase filled with water or fuel Mechanical failure Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or re
80. place plugs 115 TROUBLESHOOTING Engine Backfires Possible Cause Solution Weak spark from spark plugs Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Mechanical failure Engine Runs Irregularly Stalls or Misfires Possible Weak Spark Cause Solution Other mechanical failure Possible Lean Fuel Mixture Cause Solution Possible Rich Fuel Mixture Cause Solution Kinked or plugged fuel vent line Inspect and replace 116 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 plugs Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Incorrect fuel Clogged air filter Reverse speed limiter malfunction Electronic Throttle Control malfunction Other mechanical failure Overheated engine Engine Overheating Possible Cause Debris lodged in screen Plugged Radiator Solution Clean radiator screen and core Clean engine exterior See your Polaris dealer Solution Remove and clean the screen Pull on the top portion of the screen then remove the lower portion Use a garden hose to flush any debris from the radiator fins NOTE High pres sure washers can deform the radiator fins and reduce cooling efficiency 117 WARRANTY LIMITED WAR
81. r at 20 hours or one month PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and better performance Break in the clutches and belt by operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggressive acceleration and high speed operation during the break in period 45 OPERATION Pre Ride Inspection 4 amp WARNING If a proper inspection is not done before each use severe injury or death could result Always inspect the vehicle before each use to ensure it s in proper operating condition Pre Ride Checklist Domo teme Pme Page Front suspension inspect ubcato necessary 55 Rear suspension spect ubrcate necessary 68 Steering Ensure tee operation Inspect condition and pressure Frame nuts bots senes Inspect ensure ighiness Coolant evel Tappleable Ensure propere icable DEG Air fiter preter Inspect clean fe Air box sediment tube Drain deposits whenever visible Brake light tail lamp Check operation apply Polaris dielec tric grease when lamp is replaced Riding gear Wear helmet goggles protective 26 clothing Headlamp Check operation apply Polaris dielec tric grease when lamp is replaced 46 OPERATION Starting the Engine 4 amp WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulti
82. r mounting screws 1 2 Remove the lens cover 2 and gasket 3 Remove the lamp 3 4 Apply dielectric grease to the socket and install the new lamp 5 Test the taillight brakelight 6 Reinstall the gasket and lens cover 89 MAINTENANCE Spark Plugs Spark Plug Recommendations CAUTION Using non recommended spark plugs can result in serious engine damage Always use Polaris recommended spark plugs Refer to the specifications section beginning on page 112 for the recommended spark plug type and gap for your vehicle Spark Plug Torque Specification New Spark Plug 9 11 ft Ibs 12 15 Nm Previously Installed Spark Plug 17 20 ft lbs 23 27 Nm Spark Plug Inspection 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 See page 91 4 amp WARNING A hot exhaust system and engine can cause serious burns Wear protective gloves when removing a spark plug for inspection Remove the spark plug cap 2 Using the special wrench provided in the tool pouch rotate the spark plug counterclockwise to remove it 3 Reverse the procedure for spark plug installation using the recommended spark plug Torque to specification EN 90 MAINTENANCE Spark Plugs Spark Plug Inspection Normal Spark Plug The normal insul
83. rding to approved instructions See your authorized Polaris ATV dealer for more information WARNING POTENTIAL HAZARD Overloading the ATV or carrying towing cargo improperly WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling which could lead to loss of control or an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allowa greater distance for braking Always follow the instructions in the owner s manual for carrying cargo or pulling a trailer See page 49 WARNING POTENTIAL HAZARD Operating on frozen bodies of water WHAT CAN HAPPEN Severe injury or death can result if the ATV and or the operator fall through the ice HOW TO AVOID THE HAZARD Never operate the ATV on a frozen body of water SAFETY Operator Safety A A WARNING After any overturn or accident have a qualified service dealer inspect the entire vehicle for possible damage including but not limited to brakes throttle and steering systems WARNING Safe operation of this rider active vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control which could result in severe injury or death CAUTION Exhaust system components are very hot during
84. rranty terms will remain in effect Engine Oil 1 Mixing oil brands or using non recommended oil may cause engine damage We recommend the use of Polaris engine oil for your ATV 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty SPARK ARRESTOR Polaris warrants that the spark arrestor in this vehicle will meet the efficiency require ments of 43 CFR 8343 1 c for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with Polaris recommendations 120 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WAR RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCA TION This policy does not apply to vehicles that have received authorization for export from Polaris Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warranty or service bulletin coverage if you have any questions This policy does not apply to vehicles registered to government officials or military per sonnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Recalls How to Get Service In the Country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer If you mov
85. ses the possibility of vehicle overturn CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE Carrying loads high on the racks raises the center of gravity of the vehicle and creates a less stable operating condition e SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of con trol of the vehicle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing downhill USE EXTREME CAUTION when operating with loads that extend over the rack sides Stability and maneuverability may be adversely af fected causing the vehicle to overturn DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the front rack DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS Vehicle should never exceed 10 mph 16 kph while towing a load on a level surface Vehicle speed should never exceed 5 mph 8 kph when towing loads in rough terrain while cornering or while ascending or descending a hill OPERATION Driving Procedures ae SID UA e Wear protective riding gear See page 26 Sit upright with both feet on the footres
86. 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 4 amp WARNING Operating the ATV with a spongy brake lever can result in loss of braking which could cause an accident Never operate the ATV with a spongy feeling brake lever 29 CONTROLS Master Cylinder The brake fluid in the master cylinder 1 which is located on the left handlebar should be checked before each ride The fluid level can be seen through an indicator window 2 on the top of the master cylinder This eye will appear dark when the fluid level is full When fluid needs to be added the eye will be clear NOTE When checking the fluid level the ATV must be on level ground with the handlebars straight If the fluid level is low add DOT 4 brake fluid only See page 111 for the part numbers of Polaris products 4 amp WARNING After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of accident or severe injury 30 CONTROLS Parking Brake 4 amp WARNING Operating the ATV while the parking brake is engaged could result in an accident and serious inj
87. speedometer harnesses from the speedometer Unplug the headlamp from the wiring harness Be sure to pull on the connector not on the wiring Turn the lamp counterclockwise to remove it Apply dielectric grease to the socket and install the new lamp NOTE Make sure the tab on the lamp locates properly in the 8 86 housing Reassemble the pod MAINTENANCE Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward Use the following procedure to make the adjustment 25 ft 7 6 m 4 2 b cm M a if 1 Position the vehicle on a level surface with the headlight approximately 25 ft 7 6 m from a wall Place the transmission in PARK 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 Turn the headlight switch to high beam 4 Observe the headlight aim on the wall The most intense part of the headlight beam should be two inches 5 cm below the mark on the wall NOTE Include rider weight on the seat when measuring 5 The adjustment knob is located on the right side of the headlight pod Adjust the beam to the desired position by turning the knob either clockwise or counterclockwise 87 MAINTENANCE Lights Low Beam Adjustment The low beam can be adjusted slightly upward or downward 1 Loosen the headlamp mounting bolt 1 2 Tilt the headlamp up
88. sure is lost Remove cargo from the racks and do not tow a load with flat tires Vehicle characteristics including braking and handling may also be affected by operating with flat tires If you must operate the vehicle with a flat tire drive no further and no faster than necessary and travel on smooth and level terrain whenever possible 4 WARNING Failure to reduce travel distance vehicle speed and cargo weight when air pressure is lost in run flat tires could result in loss of control or tire damage This could lead to serious injury or death If you must operate the vehicle with flat tires remove all cargo and towed loads from the ATV and do not exceed 50 miles 80 km at 25 MPH 40 km h Have the tire s inspected by an authorized Polaris dealer as soon as possible and before further use Winches Your vehicle is equipped with both a front 1 and a rear 2 winch These winches operate independently Use the pod switch to select one of the winches Use the handlebar switch to operate the selected winch Refer to the winch manufacturer s Basic Guide to Winching Techniques provided with your ATV for complete winch operation instructions 36 FEATURES All Wheel Drive AWD System Polaris 4 wheel drive ATVs are equipped with a unique Polaris exclusive All Wheel NN Drive AWD system which is activated by a switch 1 on the right handlebar When the switch is off the ATV is
89. tation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if incon sistent with controlling state law 119 WARRANTY ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IM PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICU LAR 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 warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service you must take it to a Polaris dealer authorized to repair Polaris ATVs When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other wa
90. tem Operation 78 Crankcase Emission Control System 62 D Demand Drive Fluid 73 Diagnostic Mode 41 43 Drivetrain Break in 45 Driving Downhill 56 Driving in Reverse 60 Driving on aHillside 55 Driving on Slippery Surfaces 53 Driving Procedures 51 Driving Through Water 58 Driving Uphill 54 E Electrical Switches 27 Electromagnetic Interference 62 Emission Control Systems 62 Engaging All Wheel Drive 37 Engine Break in 45 Engine Cooling System 76 78 Engine Stop Switch 27 Equipment Modifications 10 Exhaust Emission Control System 62 F Footwell Removal 82 Front Gearcase Fluid 73 Front Wheel Hub Tightening 83 Fu l Filter sets ils tebii 33 Fuel Requirements 33 Fuel Safety eese 44 Fuel Tanks 004 33 Fuel Valve sioi iranan panaia 33 G Gear Selector 00 34 Gearcase Specification Chart 72 H Handlebars 101 Hauling Cargo esses 49 50 Headlamp Lower 89 Headlight Housing Replacement 88 Headlight Lamp Replacement 86 High Beam Adjustment 87 High Range 000 95 Hour Meter 000 40 l Idle RPM rosati eeina uek 102 Ignition Switch 27 I
91. ter for another five seconds if necessary Repeat this procedure until the engine starts NOTE If a warm 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 If the engine is over choked when warm depress the throttle lever fully while cranking to aid in starting Release the throttle lever immediately after the engine starts If the engine does not start and all conditions are favorable change the spark plug and try again 10 If the engine slows or stops position the choke knob half way in to allow proper engine warm up Vary the engine RPM slightly with the throttle to aid in warm up When the engine idles smoothly push the choke completely in CAUTION Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle Cold Weather Operation If the ATV is used year round check the oil level frequently A rising oil level could indicate the accumulation of contaminants such as water or excess fuel in the crankcase Water in the crankcase can lead to engine damage and must be drained Water accumulation increases as outside temperature decreases See your Polaris dealer for engine heater kits which provide quicker warm ups and easier starting in colder weather 48 OPERATION Hauling Cargo 2 3 Do not exceed the weight capacities specified for th
92. the part numbers of Polaris products Washing the Vehicle Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components CAUTION High water pressure may damage ATV components Polaris recommends washing the vehicle by hand or with a garden hose using mild soap Certain products including insect repellants and chemicals will damage plastic surfaces Do not allow these types of products to come into contact with the vehicle The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips e Avoid the use of harsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish Always use clean cloths and pads 104 MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning not recommended exercise extreme caution The water may damage components and could remove paint and decals Avoid directing the water stream at the following items Wheel bearings Radiator Transmission seals Brakes Cab and body panels Labels and decals NOTE f warning and safety labels are damaged
93. ts and both hands on the handlebars Start the engine and allow it to warm up Shift the transmission into gear Check your surroundings and determine your path of travel Release the parking brake Slowly depress the throttle with your right thumb and begin driving Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces 51 OPERATION Making Turns Your ATV is equipped with a rear AR axle that drives both rear wheels Ne equally at all times This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly To turn steer in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest This technique alters the balance of traction between the rear wheels allowing the turn to be made smoothly The same leaning technique should be used for turning in reverse NOTE Practice making turns at slow speeds before attempting to turn at faster speeds 4 WARNING Turning at sharp angles or at excessive speeds can result in vehicle overturn and lead to serious injury Avoid turning at sharp angles Never turn at high speeds 52 OPERATION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel or during freezing weather follow these precautions 1 2 Slow down when
94. ury or death Always check to be sure the parking brake is disengaged before operating Locking the Parking Brake 1 2 4 Place the transmission in PARK Squeeze and release the brake lever two or three times then squeeze and hold Push the park brake lock 1 forward to engage the brake Release the brake lever To release the parking brake lock squeeze and release the brake lever It will return to its unlocked position Important Safeguards The parking brake may relax if left on for a long period of time AI ways block the wheels to prevent rolling Always block the wheels on the downhill side of the ATV if leaving it parked on a hill Another option is to park the ATV in a sidehill position Never depend on the parking brake alone if the ATV is parked on a hill Always block the wheels to prevent rolling 31 CONTROLS Auxiliary Brake 4 amp WARNING Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover which could result in serious injury or death Use caution when applying the auxiliary brake Do not aggressively apply the auxiliary brake when going forward The rear wheels may skid and slide sideways causing loss of control and serious injury or death Your Polaris ATV has an auxiliary brake 1 for added safety It s located on the inside of the right floor board and is operated by the right foot The auxiliary brake serves as a backup to the mai
95. vehicle in your area We strongly advise you to strictly follow the recommended maintenance program outlined in your owner s manual This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals 6 SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your ATV Your safety is involved when these words and symbols are used Become familiar with their meanings before reading the manual A A The safety alert symbol on your vehicle or in this manual alerts you to the potential for personal injury WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death CAUTION The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle NOTE A note will alert you to important information or instructions SAFETY Operator Safety 4 amp WARNING Serious injury or death can result if you do not follow these instructions and procedures which are outlined in further detail within your owner s manual Read this manual and all labels carefully and follow the operating procedures described Never operate an ATV without proper instruction Take a training course Purchasers of a new Polaris ATV and th
96. ward or downward 3 Tighten the bolt Headlight Housing Replacement 1 2 3 Wie 0 005 c 2M NOTE The distance from the 10 88 Remove the two screws on the lower front corners of the headlight pod Lift the pod slightly while depressing the tabs at the rear of the pod Lift the pod cover and disconnect the speedometer harnesses from the speedometer Unplug the headlamp from the wiring harness Use a small screwdriver to remove the o rings from the headlight mounting tabs Pull the headlight housing up to release it from the locking tabs Lift the adjusting knob up to remove it from the locking tabs Carefully pull the assembly up and out of the pod Reverse the steps to install the new housing and reassemble the pod headlamp parting line to the end of the adjustment knob stop is 5 1 8 18 cm Adjust the headlight aim by E turning the adjusting knob i MAINTENANCE Lights Lower Headlamp Removal Installation 1 Turn the back of the headlight harness 1 in a clockwise direction His 2 Pull the harness assembly out from the E i headlight assembly ye 3 Remove the headlamp and install 1 ed the new headlamp 4 Install the new headlamp and harness assembly into the headlight assembly Turn the headlight harness counterclockwise to secure Taillight Brakelight Lamp neplacement 1 Remove the taillight lens cove
97. wly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough slippery or loose terrain WHAT CAN HAPPEN Operating on excessively rough slippery or loose terrain could cause loss of traction or loss of control which could result in an accident or overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you ve learned and practiced the skills necessary to control the ATV on such terrain Always use extra caution on rough slippery or loose terrain 4 amp 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 17 SAFETY Operator Safety 4 amp WARNING 18 POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle may overturn HOW TO AVOID THE HAZARD Never operate on hills too steep for the ATV or for your abilities Never operate the ATV on hills steeper than 25 Practice on smaller hills before attempting large hills WARNING POTENTIAL HAZARD
98. y change the handling characteristics of the vehicle Use only Polaris approved accessories and familiarize yourself with their function and effect on the vehicle 10 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Operating this ATV without proper instruction WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the ATV RiderCourse offered by Polaris through the SVIA They should then regularly practice the skills learned in the course and the operating techniques described in the Owner s Manual For more information about the ATV RiderCourse contact ATV Enrollment Express at 800 887 2887 or visit www atvsafety org 4 WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV WHAT CAN HAPPEN Severe injury and or death could occur if a child under the minimum age recommendation operates an ATV Even though a child may be within the recommended age group for operating some ATVs he she may not have the skills abilities or judgment needed to operate an ATV safely and could be susceptible to accident or injury HOW TO AVOID THE HAZARD No one under the age of 16 should operate a Polaris ATV 11 SAFETY Operator Safety 4 amp WARNING 12 POTENTIAL HAZARD Carrying a passeng
99. y component of the PVT system Doing so may reduce its strength so that a failure may occur at a high speed The PVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures See your dealer as outlined in the owner s manual This PVT system is intended for use on Polaris products only Do not install it in any other product Always make sure the PVT housing is securely in place during operation PVT Drying There may be some instances when water is accidently ingested into the PVT system Use the following instructions to dry it out before operating 1 2 96 Remove the drain plug and allow the water to drain Replace the drain plug Start the engine and shift the transmission into neutral Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds Allow the engine RPM to settle to idle speed then shift the transmission to the lowest available range Test for belt slippage If the belt slips repe

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