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Polaris 9922079 Offroad Vehicle User Manual

1. the drain plug 5 Place a drain pan 5 j under the crankcase pa SE N BI Caro leo Cole MO G Ile l o 6 Remove the drain LES pe plug Allow the oil to Tr drain completelv gt to front CAUTION Hot oil can cause burns to skin Do not allow hot oil to contact skin 7 Install a new sealing washer on the drain plug The sealing surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches 8 Reinstall the drain plug Torque to 20 ft Ibs 27 Nm Place shop towels beneath the oil filter Using an oil filter wrench available from your Polaris dealer turn the filter counter clockwise to remove it 10 Using a clean dry cloth clean the filter sealing surface on the crankcase 71 MAINTENANCE Engine Oil Oil and Filter Change 11 12 13 14 15 16 17 18 19 20 21 72 Lubricate the o ring on the new filter with a film of fresh engine oil Check to make sure the o ring is in good condition Install the new filter and rotate it clockwise bv hand until the filter gasket contacts the sealing surface then turn it an additional 1 2 turn Remove the dipstick Add two quarts 1 9 1 of recommended oil Place the transmission in PARK Lock the parking brake Start the engine Allow it to idle for one to two minutes Stop the engine Check for leaks Check the oil
2. 85 Toe Alignment 81 Towing Loads 61 Trail Etiquette 48 TTAMMB A L 3 exe ence the set Aa 7 Transmission Gear Selector 33 Transmission Oil 73 Transporting the Vehicle 113 Tread Lightly 2 48 Turning Around ona Hill 56 Turning the Vehicle 51 V Vehicle Identification Numbers 6 Vehicle Immersion 96 Ww Warning Symbols 4 Washing the Vehicle 107 108 Wheel Hub Tightening 85 Wheel Installation 86 Wheel Nut Torque Specifications 86 Wheel Removal 85
3. 32 FEATURES AND CONTROLS Fuel Tank Cap Fuel Tank Always refuel with the engine stopped and outdoors or in a well ventilated area Refuel on a level surface Remove the fuel tank cap to add fuel to the fuel tank Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Do not use fuel with ethanol content greater than 10 percent such as E 85 fuel Automatic Transmission Gear Selector The transmission gear selector is located on the right side of the vehicle B H High Gear SD L Low Gear s N Neutral R Reverse P Park To shift gears brake to a complete stop When the engine is idling move the lever to the desired gear NOTICE Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage 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 Gear Selector 33 FEATURES AND CONTROLS All Wheel Drive AWD System The All Wheel Drive system is controlled by the AWD switch When the switch is on 2X4 the ATV is in two wheel drive at all times When the switch is on AWD the ATV is in all wheel drive and the AWD indicator light in the instrument cluster will Switch be on When in AWD the deman
4. 4 Sit on the vehicle and move the engine stop switch to RUN m Do not press the throttle while starting the engine 6 Turn the ignition key past the ON position to engage the starter Activate the starter for a maximum of five seconds releasing the key when the engine starts 7 Ifthe engine does not start return the key to the OFF position and wait five seconds before attempting to start again Activate the starter for another five seconds if necessary Repeat this procedure until the engine starts NOTICE 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 Ifthe ATV is used year round check the oil level frequently A rising oil level could indicate the accumulation of contaminates such as water or excess fuel in the bottom of the crankcase Water in the bottom of the crankcase can lead to engine damage and must be drained Water accu mulation increases as outside temperature decreases See your Polaris dealer for engine heater kits which provide quicker warm ups and easier starting in colder weather 49 OPERATION Driving Procedures hu ot aS eS 50 Wear a helmet and eye protection See page 8 Sit upright with both feet on the footrests and both hands on the handlebars Start the engine and allow it to warm up Shift the transmission into gear Check your surroundings and
5. Disconnect the red positive batterv cable last Lift the batterv out of the ATV Be careful not to tip a conventional batterv sidewavs which could spill electrolvte NOTICE 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 Ad e b ae 102 MAINTENANCE Batterv Batterv Installation Using a new batterv that has not been fullv charged can damage the bat terv and result in a shorter life It can also hinder vehicle performance Follow the batterv charging instructions on page 105 before installing the batterv 1 Ensure that the battery is fully charged 2 Place the battery in the battery holder 3 With conventional batteries install the battery vent tube sealed bat teries do not have a vent tube 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 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 4 ONO Now On conventional batteries 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 Install the battery cover Sec
6. Plugged Radiator Use a garden hose to flush anv debris from the radiator fins NOTE High pres sure washers can deform the radiator fins and reduce cooling efficiencv 117 SPECIFICATIONS SPORTSMAN 800 EFI Maximum Weight Capacitv 515 Ibs 234 kg Fuel Capacitv 4 13 gal 15 6 1 Engine Oil Capacitv 2 qts 1 9 1 Coolant Capacitv 3 6 qts 3 4 1 Rear Gearcase Oil Capacitv 5 oz 150 ml Demand Drive Fluid Capacitv 9 oz 265 ml Transmission Oil Capacitv 15 oz 450 ml Front Rack Storage Box Capacitv 100 Ibs 45 kg Rear Rack Capacitv 200 Ibs 91 kg Receiver Hitch Tongue Capacitv 150 Ibs 68 kg Rear rack capacitv and tongue weight not to exceed 200 Ibs 91 kg Hitch Towing Rating 1500 Ibs 680 4 kg Unbraked Trailer Towing Capacity 1914 Ibs 868 kg Overall Length 83 in 211 cm Overall Width 48 in 122 cm Overall Height 48 in 122 cm Wheelbase 50 75 in 128 9 cm Ground Clearance 11 25 in 28 5 cm Dry Weight 770 Ibs 349 kg with cast wheels 780 Ibs 354 kg with steel wheels Minimum Turning Radius 76 in 193 cm unloaded Engine EH0760LE Displacement 760 cc Bore x Stroke 80 x 76 Alternator Output 500 Watts 3000 rpm Compression Ratio 10 1 Starting System Electric Fuel System Electronic Fuel Injection Ignition System ECU Ignition Timing
7. filter damage could occur Reinstall the air box cover and the seat 87 MAINTENANCE Fuse Replacement Fuse Feature Supported 5A Speedometer 15A Electronic Fuel Injection 20A Main Fuse Ignition Lighting 20A Accessories 12V Power Receptacle If the engine stops or will not start or if vou experience other electrical failures a fuse mav need replace ment Locate and correct anv short circuits that mav have caused the blown fuse then replace the fuse Spare fuses are provided in a com partment on the top of the access door 1 Open the front box cover and pull open the access door 2 Remove the suspect fuse from the fuse panel If the fuse is blown install a new fuse with the same amperage 3 Secure the access door Secure the box cover 88 MAINTENANCE Lights Poor lighting can result in reduced visibilitv when driving Headlight and taillight lenses become dirtv during normal operation Clean lights frequentiv and replace burned out lamps promptiv Alwavs make sure lights are adjusted properlv for best visibilitv Headlight Lamp Replacement When servicing a halogen lamp don t touch the lamp with bare fingers Oil from vour skin leaves a residue causing a hot spot that will shorten the life of the lamp 1 Remove the two screws on the lower front corners of the headlight pod Remove the screw from the rear of the pod 3 Lift the pod slightly while depressing the t
8. 8 BTDC 2000 RPM Spark Plug Gap RC7YC 035 in 0 9 mm Lubrication System Pressurized Wet Sump Driving System Type Automatic PVT Polaris Variable Transmis sion Front Suspension MacPherson strut with 8 2 21 cm travel Rear Suspension Progressive rate with 9 5 24 cm travel Based on EU Directive 76 432 EC 118 SPECIFICATIONS SPORTSMAN 800 EFI Transmission Automatic PVT with E Z Shift H L N R P Gear Reduction Low 7 49 1 Gear Reduction Reverse 5 11 1 Gear Reduction High 2 88 1 Drive Ratio Front 3 82 1 Drive Ratio Final 3 10 1 Tires Pressure Front 26x8 12 5 psi 34 5 KPa Tires Pressure Rear 26x11 12 5 psi 34 5 KPa Brakes Front Single Control Hydraulic Disc Brakes Rear Single Control Hydraulic Disc Brakes Auxiliary Foot Activated Hydraulic Disc Brake Parking Hydraulic lock all wheel Headlight 1 Single Beam on Headlight Pod 50 watt 2 Single Beam on Bumper 37 5 watt Taillights 8 26 watts Brake Light 26 9 watts Instrument Cluster LCD Clutching Altitude Shift Drive Clutch Driven Helix Weight Spring Clutch Spring Meters 0 1800 23 62 Black Black Almond 48 54 Feet 0 6000 PN 5632337 PN 7043594 PN 7043167 Progressive 1800 3700 23 58 Black Black Almond 48 54 6000 12000 PN 5632218 PN 7043594 PN 7043167 Progressive 119 POLAR
9. the radiator filler neck the radiator pressure cap and the connecting hose As coolant operating temperature increases the expanding heated excess coolant is forced out of the engine past the pressure cap and into the recoverv bottle As engine coolant temperature decreases the con tracting cooled coolant is drawn back up from the bottle past the pres sure cap and into the radiator Some coolant level drop on new vehicles is normal as the svstem is purging itself of trapped air Check the coolant level and maintain as recommended bv adding coolant to the recoverv bottle Polaris recommends the use of Polaris Premium 60 40 anti freeze cool ant 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 120 for the part numbers of Polaris products Always follow the manufacturer s mixing recommendations for the freeze protection required in your area Recovery Bottle Coolant The recovery bottle is located on the left side of the vehicle 1 Remove the left side panel See page 84 2 Maintain the coolant level between the minimum and maximum marks on the bottle when the fluid is cool 3 Add coolant as needed 78 MAINTENANCE Cooling Svstem Radiator Coolant To ensure that the coolant maintains its abilitv to protect the engine Polaris recommends that vou drain the svstem co
10. 4 Turn the headlight harness clock wise to secure the headlamp Taillight Brakelight Lamp Replacement 1 Remove the harness connector from the back of the light Connector lt s assembly B 2 Turn the lamp counter clock wise to remove it YAW 3 Apply dielectric grease to the N lt Cia socket and install the new i lamp 4 Reinstall the harness connector 5 Test the light for proper operation 93 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 118 for the recom mended spark plug tvpe and gap for vour vehicle Torque spark plugs to specification NOTICE Using non recommended spark plugs can result in serious engine damage Alwavs use Polaris recommended spark plugs Plug Condition 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 Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plugs for correct color See page 95 CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection 1 Rotate the spark plug cap 1 4 turn and pull it off the spark plug 2 Using the special wrench provided in the tool pouch rotate the sp
11. Driving on a Sidehill 54 Driving on Slipperv Surfaces 52 Driving Over Obstacles 58 Driving Procedures 50 Driving Through Water 5 Driving Uphill 00 53 E Electromagnetic Interference 63 Emissions Limited Warranty 127 128 Engaging AWD 34 Engine Break In 45 Engine Fogging 111 Engine Oil 70 72 Equipment Modifications 9 Etiquette Trail Riding 48 Exhaust Emission Control System 63 Eye Protection 9 F Fluid Brakes ce si il ka BY RRS 30 Demand Drive 74 75 Fluid Change Demand Drive 75 Foot Brake Auxiliary 32 Footwell Removal 84 Front Gearcase Demand Drive 74 75 Fuel Safety nireti Gain eens ees 11 Fuel Tank Cap 0 33 Fuse Replacement 88 G Gasoline Handling 11 Gear Selector 0 00 33 Gearcase Oil Rear 76 77 GIO VES i ia e e l 9 H Hand Brake 80 Handlebar Adjustment 82 Hauling Cargo 60 61 Headlight Housing Replacement 92 Headlight Lamp Replacement 89 Headlight Switch 27 Helmets 4x0 shin Sasa 8 High Beam Adjustment 90 High Range Use 100 l Idle RPM Adjustment 83 Immersion unne 96 Instrument Cluster 35 43 K Key Switc
12. Lock the parking brake and remount the vehicle from the uphill side keeping body weight uphill Restart the engine with the transmission still in forward Release the parking brake and proceed slowly controlling speed with the service brake until the vehicle is on more level ground OPERATION Driving Through Water Your ATV can operate through water with a maximum recom mended depth equal to the bot tom of the footrests Follow these procedures when operat ing through water 1 Determine water depths and current before entering water 2 Choose a crossing where a both banks have gradual inclines 3 Avoid operating through deep or fast flowing water NOTICE Major engine damage can result if the vehicle is not thoroughly inspected after operation in water Perform the services outlined in the maintenance chart See page 64 The following areas need special attention engine oil transmission oil demand drive fluid rear gearcase oil and all grease fittings If the vehicle tips or overturns in water or if the engine stops during or after operating in water restarting can result in serious engine damage Transport the vehicle to your dealer for service before restarting the engine If this is not possible follow the vehicle immersion inspection and drying procedures outlined on page 96 then see your dealer for service at the first opportunity 4 After leaving water test the brakes Apply them lightly seve
13. Solution Recharge the batterv to 12 8 VDC Loose batterv connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Engine Turns Over Fails to Start Possible Cause Out of fuel Solution Refuel cycle key to ON position three times for 5 seconds each then start Clogged fuel filter Replace the filter Water is present in fuel Drain the fuel system and refuel Old or non recommended fuel Replace with fresh recommended fuel Fouled or defective spark plugs Inspect plugs and replace if necessary No spark to spark plug Inspect plugs verify stop switch is on Water or fuel in crankcase Immediately see your Polaris dealer Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure See your dealer Engine Backfires Possible Cause Solution Weak spark from spark plug Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with fresh recommended fuel Incorrectiv installed spark plug wires See your dealer Incorrect ignition timing See your dealer Mechanical failure See your dealer Loose ignition connections Check all connections and tighten Water present in fuel Replace with fresh recommended fuel 115 TROUBLESHOOTING E
14. The OZS engine will not start or run OFF RUN OFF when the switch is off Both the main switch and the engine stop switch will shut off all electri cal power to the vehicle including lights Main Key Switch Use the main key switch to start the engine See page 49 for starting pro cedures Headlight Switch Use the headlight switch to turn the lights on and off and to change the lights from high beam to low beam The key must be in the ON position and the engine stop switch must be in the RUN position to operate the headlights 27 FEATURES AND CONTROLS Throttle Lever AWARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident Never start or operate an ATV that has a sticking or improperly operating throttle Always contact your dealer for service before operating the vehicle 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 Modifications to the electronic throttle control could result in failure to perform as designed which could result in an accident Do not attempt to modify the throttle control system or replace it with any after market throttle mechanisms Always ensure that the throttle cable is installed and properly routed to the throttle control Engine spe
15. Tow only from tow hooks or hitch e Max Rack Loads Front 100 Ibs 45 kg Rear 200 Ibs 91 kg 7172749 Reverse Override Warning 4X4 Caution WARNING Improper use of the override button can lead to loss of control resulting in severe injury or death Do not activate override while throttle is engaged Always apply throttle gradually while in reverse CAUTION Do not push switch to engage 4X4 AWD if the rear wheels are spinning This may cause severe drive shaft and clutch damage 7175552 25 FEATURES AND CONTROLS Switches Headlight Switch AWD Switch Main Key Switch Mode Reverse Override Engine Switch Stop Switch Mode Reverse Override Switch This vehicle is equipped with a reverse speed limiter system To gain additional wheel speed while backing release the throttle and depress the override button WARNING Pressing the override button while the throttle is open can cause loss of control which may result in serious injury or death Always release the throttle before pressing the override button 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 modes of the rider information center See page 35 AWD Switch Use the AWD switch to engage 4X4 or 2X4 See page 34 26 FEATURES AND CONTROLS Switches Engine Stop Switch gt Move the stop switch either left or right to the OFF position al to stop the engine quickly
16. become more flex ible and prevent belt burning Slow easv clutch engage ment Use the throttle quickly and effectively Towing pushing at low RPM low ground speed Use low range only Utility use plowing Use low range only Stuck in mud or snow Shift the transmission to low range and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large objects from a stopped position Shift the transmission to low range and carefully use fast brief aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Belt slippage from water or snow ingestion into the PVT system Dry out the PVT See page 100 Inspect clutch seals for damage if repeated leaking occurs Clutch malfunction See your Polaris dealer Poor engine performance Check for fouled plugs or foreign material in gas tank or fuel lines See your dealer Slippage from failure to warm up belt Always warm up the belt by operating below 30 mph for one mile 5 miles or more when temperature is below freezing Wrong or missing belt Install the recommended belt Improper break in Always break in a new belt and or clutch See page 45 114 Engine Doesn t Turn Over Possible Cause Low batterv voltage TROUBLESHOOTING
17. 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 40 The service interval is programmed at 50 hours at the factory 39 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Programmable service interval To enable or disable the service interval 1 2 3 Enter the diagnostic mode Toggle to the service interval screen 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 2 3 Enter the diagnostic mode Toggle to the service interval screen Press and hold the mode button for 2 3 seconds until the wrench icon flashes Release the button Press and release the mode button once to advance the setting by one hour Press and hold the mode button to advance the hours quickly If you scroll past the intended number press and hold the button until the hours cycle back to zero When the desired setting is displayed wait until the wrench ico
18. emissions limited warranty does not cover components whose failure does not increase the vehicle s regulated emissions For exhaust emissions emission related components include any engine parts related to the following systems e Mir induction system e Ignition system e Fuel system e Exhaust gas recirculation systems The following parts are also considered emission related components for exhaust emis sions e Aftertreatment devices e Sensors e Crankcase ventilation valves Electronic control units The following parts are considered emission related components for evaporative emis sions Fuel Tank e Vacuum Control Diaphragms e Fuel Cap e Control Cables e Fuel Line e Control Linkages e Fuel Line Fittings e Purge Valves e Clamps e Vapor Hoses e Pressure Relief Valves e Liquid Vapor Separator e Control Valves e Carbon Canister e Control Solenoids e Canister Mounting Brackets e Electronic Controls e Carburetor Purge Port Connector As related to the evaporative emission control system 127 WARRANTV U S A EPA Emissions Limited Warrantv 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 prod ucts THE REMEDIES SET FORTH IN THIS LIMITED 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 CONSEQU
19. engine and drive components will result in more efficient performance and longer life for these components NOTICE Excessive heat build up during the first three hours of operation will damage close fitted engine parts and drive components Do not operate at full throttle or high speeds during the first three hours of use 44 OPERATION Break In Period Engine and Drivetrain Break in 1 2 Fill the fuel tank with gasoline See page 33 Alwavs exercise extreme caution whenever handling gasoline Check the engine oil level on the dipstick Sec page 70 Add oil if necessarv to maintain the level between the safe and add marks Drive slowly at first Select an open area that allows room to famil iarize yourself with vehicle operation and handling Varv the throttle positions Do not operate at sustained idle Perform regular checks on fluid levels controls and areas outlined on the dailv pre ride inspection checklist See page 46 Pull only light loads Change both the oil and the filter at 20 hours or one month which ever comes first 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 dur ing the break in period 45 OPERATION Pre Ride Checklist Failure
20. fluid at the recommended level Do not overfill 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 brake failure which could result in an accident After opening a bottle of brake fluid always discard any unused portion Check the brake fluid in the master Master Cylinder cylinder before each ride 1 Position the ATV on a level surface 2 Position the handlebars so the master cylinder is level 3 View the brake fluid level through the indicator window on the top of the master cylin Indicator der The eye will appear dark Window when the fluid level is full When fluid is low the eye will be clear 4 Ifthe fluid level is low add DOT 4 brake fluid only Do not overfill 30 FEATURES AND CONTROLS Parking Brake Locking the Parking Brake 1 Place the transmission in PARK 2 Squeeze and release the brake lever two or three times then squeeze and hold 3 Push the parking brake lock forward to engage the lock 4 Release the brake lever 5 To release the parking brake lock squeeze and release the brake lever It will return to its unlocked position WARNING Operating the ATV while the parking brake is engaged could result in an accident or fire Always check to be sure the parking brake is disengage
21. level Add oil as needed to bring the level to the upper mark on the dipstick Dispose of used filter and oil properly MAINTENANCE Transmission Oil Alwavs check and change the transmission oil at the intervals outlined in the Periodic Mainte nance Chart beginning on page 64 Maintain the oil level at the bottom of the fill plug hole The fill plug is located on the right side of the ATV behind the footwell The drain plug is located on the bottom left side of the gearcase We recommend the use of Polaris Premium AGL Synthetic Gearcase Lubricant See page 120 for the part numbers of Polaris products Oil Check 1 Remove the footwell see page 84 2 Remove the fill plug Check the oil level 3 Reinstall the fill plug Torque to 14 ft Ibs 19 Nm 4 Reinstall the footwell Oil Change 1 Remove the footwell see page 84 2 Place a drain pan under the gearcase Remove the drain plug Allow the oil to drain completely 3 Clean and reinstall the drain plug Torque to 14 ft Ibs 19 Nm 4 Remove the fill plug Add 15 oz 450 ml of the recommended oil 5 Reinstall the fill plug Torque to 14 ft Ibs 19 Nm 6 Check for leaks 7 Reinstall the footwell 8 Dispose of used oil properly 73 MAINTENANCE Front Gearcase Demand Drive Fluid Alwavs c
22. 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 Your ATV may have either a sealed battery which requires little mainte nance or a conventional battery A sealed battery can be identified by its flat covers on the top of the battery A conventional battery has six filler caps on the top of the 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 termi nals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into a conventional battery 101 MAINTENANCE Batterv Batterv Removal Disconnect the batterv hold down strap Remove the batterv cover On conventional batteries remove the batterv vent tube Disconnect the black negative batterv cable first
23. several minutes so the Carbon Clean reaches the injectors Stop the engine Remove the spark plugs and add 2 3 tablespoons of Premium 4 Svn thetic OW40 engine oil To access the plug holes use a section of clear 1 4 hose and a small plastic squeeze bottle filled with the pre measured amount of oil Reinstall the spark plugs Torque to specification Apply dielectric grease to the inside of each spark plug cap and rein stall the caps onto the plugs Turn the engine over several times Oil will be forced in and around the piston rings and ring lands coating the cylinder with a protec tive film of fresh oil If Polaris fuel system additive is not used the fuel tank fuel lines and injectors should be completely drained of gasoline 111 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 64 Batterv Maintenance Remove the batterv and recharge it as outlined on page 105 Store the batterv in a cool drv place 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 Do not use plastic or coated mate rials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation Accessories Auxiliary
24. that limits the ATV s speed to approximately 7 9 mph 11 14 km h Refer to page 26 for additional information Speedometer Needle Speedometer Rider aN I iS Information Center NOTICE 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 35 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster All seg ments will light up for 2 5 seconds at start up If the instrument cluster fails to illuminate a battery over voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedome ter If this occurs take the ATV to your Polaris dealer for proper diagno sis 1 Gear Indicator This indicator displays gear shifter position H High Gear L Low Gear N Neutral R Reverse Gear P Park 2 AWD Indicator This indicator illuminates when the AWD switch is on AWD 3 Engine Hour Display Indicator Service Interval Diagnostic Mode Indicator 5 Low Battery and Over Voltage This warning usually indicates that the ATV is operating at an
25. the hitch from the ATV when not towing a trailer 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 e The total load operator accessories cargo and weight on hitch must not exceed the maximum weight capacity of the vehicle NOTICE Using an improper hitch or exceeding Maximum the maximum tongue weight capacity 4 10 cm can result in serious damage to the vehicle and will void your ATV warranty Never install a hitch longer than 4 10 cm Never install automotive accessories on your Polaris ATV Always install Polaris approved or equivalent accessories designed for ATV use 61 OPERATION Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 2 3 4 62 Stop the engine Place the transmission in PARK Lock the parking brake Always block the rear wheels on the downhill side EMISSION CONTROL SVSTEMS Noise Emission Control Svstem 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 USFS standard 5100 1c Federal law requires that
26. this spark arrestor be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public lands in the U S A is regulated by 43 CFR 420 Violations are subject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov ecft 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 Exhaust emissions are controlled by engine design An electronic fuel injection EFI system controls fuel delivery The engine and EFI com ponents are set at the factory for optimal performance and are not adjustable The vehicle compliance labels can be found on the frame tubing of the vehicle Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 This vehicle complies with the EMC requirements of European direc tives 97 24 EC and 2004 108 EC 63 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep vour 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 necessarv When inspection reveals the need for replacement parts use genuine Polaris parts available from
27. to inspect and verifv that the ATV is in safe operating condition before operating increases the risk of an accident Alwavs inspect the ATV before each use to make sure it s in safe operating condition Item Remarks Page Brake svstem lever travel Ensure proper operation ra Brake fluid Ensure proper level 30 Auxiliary brake Ensure proper operation 32 Front suspension Inspect lubricate if necessary 69 Rear suspension Inspect lubricate if necessary 69 Steering Ensure free operation Tires Inspect condition and pressure 85 Wheels fasteners Inspect ensure fastener tightness F Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 7 Coolant level if applicable Ensure proper level re Coolant hoses if applicable Inspect for leaks Throttle Ensure proper operation a Indicator lights switches Ensure operation 26 Engine stop switch Ensure proper operation 27 Air filter pre filter Inspect clean 87 Air box sediment tube Drain deposits whenever visible Headlamp Check operation apply Polaris dielec 27 tric grease when lamp is replaced 89 Brake light tail lamp Check operation apply Polaris dielec 93 tric grease when lamp is replaced Riding gear Wear approved helmet goggles and 8 protective clothing 46 OPERATION Safe Operation Practices 1 2s 10 11 12 13 14 Complete the recomme
28. to the left or right 5 Torque the front two bolts to 10 12 ft Ibs 14 17 Nm then Handlebar torque the rear two bolts A Bolts gap of up to 1 8 3 mm will remain at the rear of the clamp blocks 82 Throttle Bodv idlie RPM MAINTENANCE Idle RPM is preset by the manufacturer If the engine idle speed is not satisfactory please see your Polaris dealer for adjustment Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar 1 2 Locate the throttle cable adjuster at the handlebar Squeeze the end of the rub ber boot and slide it far enough to expose the end of the inline cable adjuster Loosen the adjuster lock nut 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 While adjusting freeplay be sure to flip the throttle lever back and forth Tighten the lock nut Squeeze the end of the rub ber boot and slide it over the cable adjuster to its original position NA Boot Lock Nut Adjuster 83 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 vour Polaris dealer for service before operating the vehicle 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 t
29. 550 EFI 2009 2010 80 8 TN55_ DN55 SPORTSMAN X2 TOURING 550 2010 77 2 MN6 SPORTSMAN 800 2008 2009 2010 83 6 TN85 DN85 SPORTSMAN X2 TOURING 850 2010 77 2 CLI6 SPORTSMAN 800 6X6 2009 2010 80 1 ZN85 ZX85 SPORTSMAN 850 EFI 2009 2010 80 4 RH50 HH50 RANGER 500 EFI 4X4 2009 2010 76 5 HA6 RANGER 800 EFI 4X4 2010 76 5 WH76 RANGER 800 EFI CREW 2010 76 5 HR RANGER 800 6X6 2010 76 5 HY _ RANGER HD 800 4X4 2010 76 5 VH6 RANGER RZR 2008 2009 2010 85 8 Authorized Signatory hlano 4 Aevrodsy Alexander A Kennedy Product Compliance Polaris Industries Inc Engineering Operations 301 5th Avenue SW Roseau MN 56751 121 WARRANTV LIMITED WARRANTV 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 registra
30. ATV e Never operate an ATV without proper instruction Take a training course e This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age e Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course INTRODUCTION Vehicle Identification Numbers Record vour vehicle s identification numbers and kev number in the spaces provided Remove the spare kev and store it in a safe place An ignition key can be duplicated only by ordering a Polaris key blank using your key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost Engine Serial Number Key Number Vehicle Model Number Frame VIN Engine Serial Number Key Number SAFETV Safetv Training ATV safetv training is a top prioritv for Polaris Polaris stronglv encourages you and any family members who will be riding the ATV to take a training course If you purchased a new Polaris ATV in the United States your dealer provided instruction to you about the authorized ATV RiderCourse that is available to you and your eligible family members This training is included in the purchase price of your ATV 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 in th
31. ENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR RANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRAN TIES 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 incon sistent 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 when the vehicle has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of Polaris Owners are responsible for performing the scheduled maintenance identified in the owner s manual Polaris may deny warranty claims for failures that have been caused by the owner s or operator s improper maintenance or use by accidents for which Polaris has no responsibility or by acts of God Any qualified repair shop or person may maintain replac
32. IS PRODUCTS Part Number Description Engine Lubricant 2870791 Fogging Oil 12 oz Aerosol 2876244 PS 4 PLUS Performance Synthetic 2W 50 4 Cycle Oil qt 2876245 PS 4 PLUS Performance Synthetic 2W 50 4 Cycle Oil gal Gearcase Transmission Lubricants 2873602 Premium AGL Synthetic Gearcase Lubricant qt 95 l 2873603 Premium AGL Synthetic Gearcase Lube gal 3 8 I 2877922 Demand Drive Plus Fluid qt 95 l 2877923 Demand Drive Plus Fluid gal 3 8 l 2871653 Premium ATV Angle Drive Fluid 8 0z 237 ml 2872276 Premium ATV Angle Drive Fluid 2 5 gal 9 5 I 2870465 Pump for Gallon 3 8 I Jug Coolant 2871323 60 40 Coolant gal 3 8 I 2871534 60 40 Coolant qt 95 I Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 2871322 Premium All Season Grease 3 0z 89 ml cartridge 2871423 Premium All Season Grease 14 0z 414 ml cartridge 2871460 Starter Drive Grease 2871515 Premium U Joint Lube 3 0z 89 ml cartridge 2871551 Premium U Joint Lube 14 0z 414 ml cartridge 2871329 Dielectric Grease Nyogel 2872073 Chain Lube Aerosol 6 25 0z 185 ml 2872348 Chain Lube Aerosol 16 0z 473 ml Additives Miscellaneous 2871326 Carbon Clean Plus 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 Loctite 565 Thread Sealant 2859044 Polaris Battery Tend
33. NSTRUCTIONS AND WARNINGS For your nearest Polaris dealer PELARIS all 800 POLARIS The Way Out or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9922249 Rev 02 Printed in USA WELCOME Thank vou 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 e All terrain vehicles ATVs e RANGER utility vehicles e Victory Motorcycles We believe Polaris sets a standard of excellence for all utility and recre ational vehicles manufactured in the world today Many years of experi ence 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 ser vice needs during and after the warranty period We also take great pride in our complete line of apparel parts and
34. Pantone 426C all c Sportsman 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 AWARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm A card containing important ATV safetv information should be attached to the owner s manual on the next page If you cannot locate this card or if it has been removed please call 1 800 342 3764 for assistance 5 RECYCLED The text is printed on 100 recycled with 40 post consumer waste PCW Pantone 426c 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 e without proper training or instruction e at speeds too fast for your skills or the conditions e on public roads a collision can occur with another vehicle e with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS e use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns e avoid paved surfaces pavement may seriously affect handling and control READ OWNER S MANUAL FOLLOW ALL I
35. RPM too low to keep the battery charged It may also occur when the engine is at idle and high elec trical 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 show the level of fuel in the fuel tank When the last segment clears a low fuel warning is activated All segments will flash FUEL will display in the LCD and the speedometer needle will blink Refuel immediately 8 Check Engine Warning Indicator This indicator serves two pur poses The word HOT displays if the engine overheats It also appears if an EFl related fault occurs Do not operate the ATV if this warning appears Serious engine damage could result 9 Mode Indicator 36 FEATURES AND CONTROLS 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 26 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 trip meter mode Press and hold the mode button override button until the total changes to 0 In the Rider Information Center the trip meter display
36. SAFETY 13 SAFETV Safetv Warnings Physical Control of the ATV Removing a hand from the handlebars or feet from the footrests during operation can reduce your ability to control the vehicle or cause loss of balance and ejection from the ATV If the operator s foot is not firmly planted on the footrest it could also contact the rear wheels Never remove your hands from the handlebars while operating and always keep both feet on the footrests Turning Improperly Turning improperly could cause loss of traction loss of control accident or overturn Always follow proper procedures for turning as described in the owner s manual Never turn abruptly or at sharp angles Never turn at high speeds Practice turning at slow speeds before attempting to turn at faster speeds Jumps and Stunts Attempting wheelies jumps and other stunts increases the risk of an accident or overturn Never attempt wheelies jumps or other stunts Avoid exhibition driving Improper Hill Climbing Improper hill climbing could cause loss of control or overturn Always follow proper procedures for climbing hills as described in the owner s manual See page 53 14 SAFETV Safetv Warnings Descending Hills Improperly Improperly descending a hill could cause loss of control or overturn Always follow proper procedures for travel ing down hills as described in the owner s manual NOTE A special technique is required
37. TV is not equipped with highway approved lights Operate this vehicle off road only Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness Clean headlights frequently and replace burned out headlamps promptly 20 SAFETV Safetv Warnings Operating a Damaged ATV Operating a damaged ATV can result in an accident After anv overturn or accident have a qualified service dealer inspect the entire machine for possible damage including but not limited to brakes throttle and steering svstems Physical Skills 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 Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle Hot components can cause 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 Unauthorized Use of the ATV Leaving the keys in the ignition can lead to unauthorized use of the vehicle which could result in an accident or overturn Always remove the ignition key when the vehicle is not in use 21 SAFETV Safetv Labels and Locations Warning labels have been placed on the ATV for vour protection Read and follow the instructions o
38. abs at the rear of the pod 4 Lift the pod cover and disconnect the speedometer harnesses from the speedometer CAUTION Hot components can cause burns to skin Allow lamps to cool before servicing 5 Unplug the headlamp from the wiring harness Be sure to pull on the connector not on the wiring 6 Turn the lamp counter clockwise to remove it 7 Apply dielectric grease to the socket and install the new lamp Make sure the tab on the lamp locates properly in the housing 8 Reassemble the pod 89 MAINTENANCE Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward Use the following procedure to make the adjustment 1 Position the vehicle on a level surface with the headlight approxi mately 25 ft 7 6 m from a wall Place the transmission in PARK 2 5 cm 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 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 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 counter clockwise 90 Lights Low Beam Adjustment The low beam can be adjusted slightly u
39. acces sories available through our online store at www purepolaris com Have your accessories and clothing delivered right to your door POLARIS The Way Out POLARIS THE WAY OUT and SPORTSMAN are registered trademarks of Polaris Industries Inc Copyright 2009 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 discrep ancies may result between the actual vehicle and the information presented in this publi cation 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 2010 SPORTSMAN 800 EFI Owner s Manual P N 9922249 2 TABLE OF CONTENTS Introduction ia 56 cb sa iii a i ew imb eed ot 4 Safety 221d 255 ia aoa Game ere he we ae 7 Features and Controls 055 26 Operation 2 ii 644s eos aw ee eee tas Gee 44 Emission Control Systems 63 Maintenance iets ka a etn ts 64 Troubleshooting 002eeee0es 114 Specifications 200 ce eee eee 118 Polaris Products 2220000eeee 120 Declaration of Conformity 121 Warranty ecic 022 cc640 4 5063 6 02055 228s 122 M
40. aintenance Log 22 000000e 129 IMAEX bites ete tee ar E nae 132 INTRODUCTION The following signal words and svmbols appear throughout this manual and on your vehicle Your safety is involved when these words and sym bols are used Become familiar with their meanings before reading the manual A The safety alert symbol indicates a potential personal injury hazard WARNING A WARNING indicates a hazardous situation which if not avoided may result in death or serious injury CAUTION A CAUTION indicates a hazardous situation which if not avoided may result in minor or moderate injury NOTICE A NOTICE indicates a situation that may result in property damage The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard INTRODUCTION Failure to heed the warnings and safetv precautions contained in this manual can result in severe injurv or death A Polaris ATV is not a tov and can be hazardous to operate This vehicle handles differentiv than other vehicles such as motorcvcles and cars A collision or rollover can occur quickiv even during routine maneuvers like turning or driving on hills or over obstacles if vou fail to take proper precautions e Read this owner s manual Understand all safety warnings precautions and operating procedures before operating a Polaris ATV Keep this manual with the
41. al See page 56 If the ATV begins rolling downhill e Keep body weight uphill e Never apply engine power e Never apply the rear brake while rolling backwards Apply the single lever brake gradually When fully stopped apply the rear brake as well and then lock the parking brake e Dismount on uphill side or to either side if ATV is pointed straight uphill e Turn the ATV around and remount following the procedure described in the owner s manual See page 56 Operating on Steep Hills Operating on excessively steep hills could cause an overturn Never operate on hills too steep for the ATV or for your abilities Never operate the ATV on hills steeper than 25 degrees 16 SAFETV Safetv Warnings Operating on Slipperv Terrain Failure to use extra caution when operating on excessivelv rough slipperv or loose terrain could cause loss of traction loss of control accident or overturn Do not operate on excessivelv rough slipperv or loose terrain Alwavs use extra caution on rough slipperv or loose terrain Operating in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn Unfamiliar terrain mav contain hidden rocks bumps or holes that could cause loss of control or overturn Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions 17 SAFETV Safetv Wa
42. an test gt Demand drive fluid 25 H Monthly 250 400 Inspect level change yearly gt Rear gearcase oil 25H Monthly 250 400 Inspect level change yearly gt Transmission oil 25H Monthly 250 400 Inspect level change yearly gt Engine breather 25H Monthly 250 400 Inspect clean if needed E filter if equipped gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service m Have an authorized Polaris dealer perform these services 66 Periodic Maintenance Chart MAINTENANCE Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km gt General 50 H 3M 500 800 Lubricate all fittings pivots lubrication cables etc E Throttle Cable 50 H 6M 500 800 Inspect adjust lubricate E JETC Switch replace if necessary E Throttle Body 50 H 6M 500 800 Inspect duct for proper seal Intake Duct ing air leaks Drive belt 50 H 6M 500 800 Inspect adjust replace as needed Cooling system 50 H 6M 1000 1600 Inspect coolant strength if applicable seasonally pressure test system yearly gt Engine oil change 100 H 6M 1000 1600 Perform a break in oil change at one month gt Oil filter change 100 H 6M 1000 1600 Replace with oil change E Valve clearance 100 H 12M 1000 1600 Inspect adjust E Fuel system 100 H 12M 1000 1600 Check for leaks at tank cap lines fi
43. apply to you if inconsistent with controlling state law ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limi tations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service you must take it to a Polaris dealer authorized to repair Polaris ATVs When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Engine Oil 1 Mixing oil brands or using non recommended oil may cause engine damage We rec om
44. ark plug counter clockwise to remove it 3 Reverse the procedure for spark plug installation Torque to specifi cation 94 MAINTENANCE Spark Plugs Spark Plug Inspection Normal Spark Plug The normal insulator tip is grav tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indi cates the proper tvpe and heat range for the engine and the service The tip should not be flakv and white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect fuel 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 or incorrect throttle body adjustments 95 MAINTENANCE Vehicle Immersion 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 Move the ATV to dry land or at the very least to water below the footrests 2 Check the air box If water is present dry the air box and replace the filter with a new filter Remove the spark plugs Dry the spark plugs Reinstall the plugs or install new plugs Attempt to start
45. bels 22 25 No Passenger Warning 24 Age 16 Warning 24 Clutch Cover Warning 25 Discretionary Warning 22 General Warning 22 Rack Warning Front and Rear 25 Reverse Override Warning 25 Tire Pressure Load Warning 23 Safety Training 0 0000 7 133 INDEX S Safety Warnings 11 21 Service Interval Programming 40 Severe Use Lena 64 Side Panel Removal 84 Sidehilling L nnanuaaaaa 54 Signal Words 4 Spark Arrestor 000000 97 Spark Plug Inspection 94 95 Spark Plug Recommendations 94 Spark Plug Torque Specification 94 Spark Plugs 94 95 Specifications 800 EFI 119 Spring Adjustment Rear Shock 82 Starting the Engine 49 Steering Assemblv 84 Storage 107 112 Storage Tips 110 112 Switches AWD Switch 26 34 Engine Stop Switch 27 Headlight Switch 27 Main Key Switch 27 Mode Switch 26 Reverse Override Switch 26 Stop Switch 0 0 27 134 T Taillight a 93 Throttle Bodv Adjustment 83 Throttle Cable Freeplav Adjustment 83 Throttle Lever 0000000 28 Tire Tread Depth 85 Tires wk wi je 9 460 409 0558 85 86 Wheel Installation 86 Wheel Nut Torque 86 Wheel Removal
46. ch 26 34 B Battery cece eee 101 106 Charging Conventional 105 Charging Sealed 106 Charging Sealed 105 Fluid Conventional 104 Installation 103 Removal 102 Storage 6 104 Belt Bife sis iii seateas tia des 33 Boots 5 3 3 is te chalets Gea ae aa 9 Brake Fluid Auxiliary Foot Brake 32 Brake Fluid Main Brake System 30 Brake Lever 00 29 Brake Foot 32 80 Brake Hand Lever 80 Brake Parking 31 Brakelight 00 0000 93 BEAK CS runan a a a aa 80 Break In Period 44 45 c Camber Adjustment 82 Cat 0 ewido dee e aa hie EEES 60 61 Caster Adjustment 82 Chrome Wheel Care 109 Cleaning and Storage 107 112 Clothing Lk Ki sest a nai 9 Clutching L L 119 Codes aae A Meet bi atar ta 41 43 Cold Weather Operation 49 Consumer Product Safetv 7 Coolant Bottle 78 Coolant Radiator 79 Cooling System 78 79 Corrosion Removal Chrome 109 Crankcase Emission Control System 63 132 D Demand Drive Capacities 74 Demand Drive Fluid 74 75 Downloading Codes 41 43 Drive Belt Wear Burn 114 Drivetrain Break In 45 Driving Downhill 55 Driving in Reverse 59
47. 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 Small fluctuations in the RPM from day to day may be normal because of changes in humidity temper ature and elevation 37 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will displav when the gauge is in the diagnostic mode To exit the diagnostic mode turn the kev switch off and on Anv move ment of the tires will also cause the gauge to exit the diagnostic mode To enter the diagnostics mode 1 Turn the key switch off and wait 10 seconds 2 Lock the parking brake 3 Place the transmission in neutral 4 Hold the mode reverse override button and turn the key switch on Release the switch as soon as the display is activated 5 Use the mode button to toggle through the diagnostic screens 38 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Batterv Voltage Screen View this screen to check batterv voltage level Tachometer Screen View the tachometer to check engine speed AWD Diagnostic Screen The gauge indicates whether or not current is flowing through the all wheel drive coil This screen is for informational purposes only Please see your dealer for all major repairs Gear Circuit Diagnostic Screen This screen
48. crossing the side of anv hill unless absolutelv necessarv If crossing a sidehill is unavoidable follow these precautions 1 2 3 4 5 54 Slow down Avoid crossing the side of a steep hill Shift body weight uphill Keep your feet on the footrests If the vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately OPERATION Driving Downhill When driving downhill follow these precautions 1 Avoid steep hills 25 maximum 2 Shift body weight uphill 3 Drive straight downhill 4 Slow down Excessive speed when traveling downhill can cause loss of control 5 Squeeze the brake lever gradually Applying the brakes too firmly may cause the rear wheels to lock which could result in loss of con trol 55 OPERATION Turning Around on a Hill K Turn If the vehicle stalls while climbing a hill never back it down the hill Use the K turn to turn around 56 Stop and lock the parking brake while keeping body weight uphill Leave the transmission in forward and shut off the engine Dismount on the uphill side of the vehicle or on the left if the vehi cle is pointing straight uphill Staying uphill of the vehicle turn the handlebars full left While holding the service brake release the parking brake lock and slowly allow the vehicle to roll around to your right until it s point ing across the hill or slightly downward
49. d Short to Ground The wire is shorted to ground between the electronic control unit and the item listed in the chart Shorted Load The wires leading to the item listed in the chart are shorted together or the item has shorted internallv Short to Batterv The wire leading from the item listed in the chart to the electronic control unit is shorted to a wire at batterv voltage 42 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Blink Failure Description Code 12 BEGIN SEQUENCE 22 Throttle Position Sensor Low 22 Throttle Position Sensor High 22 Throttle Position Sensor Out of Adjustment 25 Gear Sensor Signal 31 Svstem Voltage Low 31 Svstem Voltage High 36 Ignition Coil A Prim Sec Circuit Malfunction Open Load Short to Ground 36 Ignition Coil A Prim Sec Circuit Malfunction Shorted Load Short to Batterv 37 Ignition Coil B Prim Sec Circuit Malfunction Open Load Short to Ground 37 Ignition Coil B Prim Sec Circuit Malfunction Shorted Load Short to Batterv 41 Air Temp Sensor Low Voltage 41 Air Temp Sensor High Voltage 42 Engine Coolant Temp Low Voltage 42 Engine Coolant Temp High Voltage 44 Crank Position Sensor Circuit Fault 45 Barometric Pressure Manifold Air Pressure Sensor Low 46 Barometric Pressure Manifold Air Pressure Sensor High 47 IAC Stepper Motor Open Load 47 IAC Stepper Mo
50. d before operating The parking brake may relax if left on for a long period of time Always block the wheels to prevent rolling Always block the wheels on the downhill side of the ATV if leaving it parked on a hill Another option is to park the ATV in a sidehill position Never depend on the parking brake alone if the ATV is parked on a hill Always block the wheels to prevent rolling 31 FEATURES AND CONTROLS Auxiliary Foot Brake AWARNING Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover which could result in serious injury or death Never back down a hill 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 which may result in serious injury or death The auxiliary brake system is intended to be used as a backup for the main brake system Should the main system fail use the auxiliary foot brake The auxiliary foot brake is located Auxiliary Foot Brake on the inside of the right footrest 4 Operate this brake with your right foot 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 Maintain the fluid level between the maximum and minimum marks
51. d 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 There is no limit to the length of time the vehicle may remain in AWD Tip The override switch allows activation of AWD in reverse if the AWD switch is on See page 26 Engaging AWD The AWD switch may be turned on or off while the vehicle is moving Initially the vehicle s electronic system will not enable AWD until the engine RPM is below 3100 Once enabled 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 NOTICE 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 34 FEATURES AND CONTROLS Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel In addition to showing vehicle speed the speedometer needle flashes when a warning condition exists The instrument cluster measures distance in miles as well as hours of operation It also includes a reverse speed limiter function
52. d change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 64 Maintain the fluid level at the bottom of the fill hole threads The oil capacity is 5 oz 150 ml Do not overfill The fill plug is located on the rear of PIN Plug the gearcase The drain plug is Drain Plug located on the bottom of the gear case We recommend the use of Polaris ATV Angle Drive Fluid or GL5 80 90 weight gear lube See page 120 for the part numbers of Polaris prod ucts Oil Check 1 Position the vehicle on a level surface 2 Remove the fill plug Check the oil level 3 Add the recommended oil as needed to bring the level to the bottom of the fill hole threads Do not overfill 4 Reinstall the fill plug Torque to 14 ft Ibs 19 Nm 76 MAINTENANCE Rear Gearcase Oil Oil Change 1 Position the vehicle on a level surface 2 Place a drain pan under the drain hole 3 Remove the drain plug Allow the oil to drain completely 4 Clean and reinstall the drain plug with a new sealing washer Torque to 14 ft lbs 19 Nm 5 Remove the fill plug Add 5 oz 150 ml of the recommended oil Do not overfill 6 Reinstall the fill plug Torque to 14 ft Ibs 19 Nm 7 Check for leaks 8 Dispose of used oil properly 77 MAINTENANCE Cooling Svstem The engine coolant level is controlled or maintained bv the recoverv svstem The recoverv svstem components are the recoverv bottle
53. 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 OPERATION Turning the Vehicle Your ATV is equipped with a solid rear axle which drives both rear wheels equally at all times This means that the wheel on the outside of the turn must travel a greater dis tance 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 wT ess allowing the turn to be made smoothly The same leaning technique should be used for turning in reverse Practice making turns at slow speeds before attempting to turn at faster speeds WARNING Turning improperly can result in vehicle overturn Never turn abruptly or at sharp angles Never turn at high speeds 51 OPERATION Driving on Slipperv Surfaces Sidewavs Turn in skid Xi direction of C OC C JFEC SAT ad Ee LA O O ANA x O Whenever riding on slippery surfaces such as wet trails or loose gravel or during freezing weather follow these precautions 1 Do not operate on excessively rough slippery or loose terrain 2 Slow down when ent
54. dge instead of string 4 Measure the distance from the string to the rim at the front 1 and rear 2 of the front rim The rear measurement aan ar TE al se mT IR A Wy e 2 gt O 1 e should be 1 16 1 8 2 3 mm more than the front measurement on each side of the vehicle to obtain the recommended 1 8 to 1 4 3 6 mm toe out alignment 5 Repeat the measurement procedure on the other side of the vehicle 6 Ifyou discover improper alignment see your Polaris dealer for ser vice 81 MAINTENANCE Camber and Caster The camber and caster are non adjustable Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counter clockwise to increase or decrease spring tension Accessory springs are available through your Polaris dealer Handlebars The handlebars can be adjusted for rider preference WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars resulting in loss of control and serious 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 handlebar bolts 3 Adjust the handlebar to the desired height 4 Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully
55. e or repair the emission con trol devices or systems on your vehicle Polaris recommends that you contact an autho rized Polaris dealer to perform any service that may be necessary for your vehicle Polaris also recommends that you use only Pure Polaris parts It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle s emission controls Tampering with emission controls is prohibited by federal law If you have any questions regarding your warranty rights and responsibilities please contact the Polaris Warranty Department at 1 888 704 5290 128 MAINTENANCE LOG Present this section of your manual to your dealer each time your vehicle is serviced This will provide you and future owners with an accurate log of maintenance and ser vices performed DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 129 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 130 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 131 INDEX A Accessories L 112 Ait Filter 2 2 sies is ack e eae ea 87 All Wheel Drive System 34 Auxiliary Foot Brake 80 AWD Swit
56. e United States you can enroll in the ATV RiderCourse for a fee Call ATV Enrollment Express at 800 887 2887 or visit www atvsafety org If you purchased a Polaris ATV outside the United States please contact your dealer or local law enforcement agencies for information about safety training A Polaris ATV is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area We strongly advise you to strictly follow the recommended maintenance program outlined in your owner s manual This preventive maintenance program is designed to ensure that all critical components on your vehi cle are thoroughly inspected at specific intervals FOR MORE INFORMATION ABOUT ATV SAFETY in the United States 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 SAFETV Safe Riding Gear Alwavs wear appropriate clothing when riding an ATV Wear protective clothing for comfort and to reduce the chance of injurv Eve Protection Gloves Long Pants Helmet Wearing a helmet can prevent a severe head injurv Whenever riding a Polaris vehicle alwavs wear a helmet that meets or exceeds established safetv 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 ma
57. ed and vehicle move ment are controlled by pressing the throttle lever The throttle lever is spring loaded Engine speed returns to idle when the lever is released A oy i This ATV is equipped with Polaris e Electronic Throttle Control ETC A 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 tie 28 FEATURES AND CONTROLS Brake Lever AWARNING Operating the ATV with a spongy brake lever can result in loss of braking which could cause an accident Never operate the ATV with a spongy feeling brake lever Always contact your dealer for service before operating the vehicle Squeeze the brake lever toward the handlebar to apply the front and rear brakes These brakes are hydraulically activated disc type brakes that are activated by only one lever Always test brake lever travel and master cylinder fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before riding Contact your dealer for proper diagnosis and repairs 29 FEATURES AND CONTROLS Master Cvlinder Brake Fluid AWARNING An over full master cylinder may cause brake drag or brake lock up which could result in an accident Maintain brake
58. er Charger 2870791 Fogging Oil 12 oz Aerosol 120 DECLARATION OF CONFORMITV Polaris Industries Inc 2100 Hwy 55 Medina MN 55340 U S A Telephone 763 542 0500 CE We Polaris Industries Inc declare that the vehicles listed below conform to the essential health and safetv requirements applicable to off road all terrain vehicles APPLICABLE EUROPEAN DIRECTIVES TEST EVALUATION METHODS 98 37 EC as amended Machinery Directive EN 1050 hazard analysis CD 77 311 EEC driver perceived noise level 2004 108 EC as amended EMC Directive CISPR 12 2001 CAN CSA C108 4 EN 55012 2002 EN 61000 6 2 2001 M92 PRODUCT IDENTIFICATION VEHICLE SERIES TRADE NAME MODEL SOUND YEARS PRESSURE dB A __KA05__ OUTLAW 50 2008 2009 2010 76 8 KAO OUTLAW 90 2008 2009 2010 76 8 FAO SPORTSMAN 90 2008 2009 2010 76 8 O VA RZR 170 2009 2010 81 3 PB20 PHOENIX 200 2008 2009 2010 76 8 BA32 TRAIL BLAZER 330 2008 2009 2010 76 8 CA32 TRAIL BOSS 330 2008 2009 2010 76 8 BA50 SCRAMBLER 500 2008 2009 2010 79 6 G OUTLAW 450 2008 2009 2010 80 7 GJ52_ GP52 OUTLAW 525 2008 2009 2010 80 7 LH27 SPORTSMAN 300 2008 2009 2010 81 1 LH46 SPORTSMAN 400 2008 2009 2010 80 2 __MNSO__ SPORTSMAN 500 EFI 2008 2009 2010 80 4 ZNS5 ZX55 SPORTSMAN
59. ering slippery areas 3 Engage AWD before wheels begin to lose traction NOTICE Severe damage to drive train may occur if the AWD is engaged while the wheels are spinning Allow the rear wheels to stop spinning before engaging AWD or engage AWD before wheels begin to lose traction 4 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 5 Never apply the brakes during a skid Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward 52 OPERATION Driving Uphill 25 Maximum Braking and handling are greatly affected when operating in hilly ter rain Improper procedure could cause loss of control or overturn When ever traveling uphill follow these precautions Drive straight uphill Avoid steep hills 25 maximum Always check the terrain carefully before ascending any hill Never climb hills with excessively slippery or loose surfaces Keep both feet on the footrests Shift body weight uphill Proceed at a steady rate of speed and throttle opening Opening the throttle suddenly could cause the ATV to flip over backwards 8 Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle SUS Se SNS 53 OPERATION Driving on a Sidehill Sidehilling Driving on a sidehill is not recommended Improper procedure could cause loss of control or overturn Avoid
60. f the labels on the ATV carefully If any of the labels depicted in this manual differ from the labels on your ATV always read and follow the instructions of the labels on the ATV If an informational or graphic label becomes illegible or comes off con tact your Polaris dealer to purchase a replacement Replacement safety labels are provided by Polaris at no charge The part number is printed on the label General Warning Discretionary Warning WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate e without proper training or instruction e at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle e 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 ter rain and in turns e avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS WARNING e Never operate this ATV on HILLS steeper than 25 degrees 25 To pre vent overturn on hilly terrain use throttle and brakes gradually and shift weight uphill e REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent los
61. for ambient tempera ture operation See page 120 for the part numbers of Polaris products NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands Oil Level Access the oil dipstick and fill tube Dipstick from the left side of the ATV 1 Position the vehicle on a level surface 2 Lift the lever lock to remove the dipstick Wipe it dry with a clean cloth 3 Reinstall the dipstick com pletely but do not lock it The dipstick must be inserted com pletely to keep the angle and depth of the stick consistent 4 Remove the dipstick and check the oil level Maintain the oil level in the safe range Do not overfill Tip Due to the dipstick entry angle into the crankcase the oil level will read higher on the bottom side of the dipstick Always read the level on the upper surface of the dip stick Check Level 5 After reinstalling the dipstick on Top Side seat the lever lock 70 MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 64 Always change the oil filter whenever changing oil 1 Position the vehicle on a level surface 2 Start the engine Allow it to warm up at idle for two to three min utes 3 Stop the engine Clean the area around Drain Plug Location
62. g loss of control or overturn 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 57 Travel slowly e Balance your weight carefully e Avoid sudden movements e Maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes e Wet brakes may have reduced stopping ability After leaving water test the brakes Apply them lightly several times while driving slowly The friction will help dry out the pads 19 SAFETV Safetv Warnings Improper Cargo Loading Overloading the ATV or carrving towing cargo improperlv mav cause changes in handling which could cause loss of control or an accident s Never exceed the stated load capacity for this ATV e Cargo should be properly distributed and securely attached e Reduce speed when carrying cargo or pulling a trailer Allow a greater dis tance for braking e Always follow the instructions in the owner s manual for carrying cargo or pull ing a trailer Operating on Frozen Bodies of Water Operating on frozen bodies of water may result in serious injury or death if the ATV and or the operator fall through the ice Never operate the ATV on a frozen body of water Poor Visibility Operating the ATV in darkness or inclement weather could result in a collision or accident especially if operating on a road or street This A
63. h 000 27 VST UT ja speed b pe eyes dyes ave e 56 L Lights 89 93 Headlight Housing Replacement 92 Headlight Lamp 89 High Beam Adjustment 90 Low Beam Adjustment 91 Lower Headlamp Replacement 93 Taillight Brakelight Worklight 93 Low Beam Adjustment 91 Low Range Use 100 Lower Headlamp Replacement 93 Lubrication Guide 69 M Maintenance Chart 64 68 Master Cylinder 30 Mode Switch 26 Modifications 0 9 N Noise Emission Control System 63 O Oil Engines 232538 bes hoia 70 72 Rear Gearcase 76 77 Transmission 73 Oil and Filter Change 71 72 Oil Level Engine 70 Oil Recommendations 70 Operation on Public Lands 63 Override Switch 26 P Parking Brake 31 Parking on an Incline 62 Periodic Maintenance Chart 64 68 Polaris Product List 120 Polishing the Vehicle 108 Pre Ride Checklist 46 PVT Break In 45 PVT Drying ss ee pas ty eta ged 100 PVT System 98 100 R Reverse Operation 59 Reverse Override Switch 26 Rider Information Center 36 43 Riding Areas sas ie ta gies 48 Riding Gear 8 9 S Safe Operation Practices 47 Safety La
64. he panel downward and rearward to remove it When reinstalling side panels align the fasteners and press firmly to secure them Footwell Removal 1 2 3 84 Remove the four screws on the bottom of the footwell Use a flat screwdriver or sidecutters to remove the plastic rivets securing the footwell to the fenders Remove the footwell MAINTENANCE Tires AWARNING Operating your ATV with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle Always use original equipment size and type when replacing tires Refer to the specifications section beginning on page 118 for recom mended tire type size and pressure Tire Tread Depth Always replace tires 1 8 3 mm when tread depth is worn to 1 8 3 mm or less A WG Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical com ponent operations All service must be performed by your authorized Polaris dealer Wheel Removal 1 Stop the engine 2 Place the transmission in PARK 3 Lock the parking brake 4 Loosen the wheel nuts slightly WARNING Do not service axle nuts that have a cotter pin installed See your Polaris dealer 5 Elevate the side of the vehicle b
65. heck and change the demand drive fluid at the intervals out lined in the Periodic Maintenance Chart beginning on page 64 We rec ommend the use of Demand Drive Plus Fluid Use of other fluids may result in improper operation of components See page 120 for the part numbers of Polaris products Maintain the fluid level at the bottom of the fill hole threads See below for capacity Demand Drive Capacity Demand Drive 9 oz 265 ml The fill plug is located on the right side of the demand drive unit The drain plug is located on the bottom right side of the unit Fluid Check 1 Position the vehicle on Fill a level surface Remove the fill plug Check the fluid level 2 Add the recommended fluid as needed to bring the level to the bottom of the fill hole threads 3 Reinstall the fill plug sil Torque to 8 10 E Ibe Fill Level Sprain Plug 11 14 Nm 74 MAINTENANCE Front Gearcase Demand Drive Fluid Fluid Change 1 Position the vehicle on a level surface Remove the fill plug 2 Place a drain pan under the demand drive unit Remove the drain plug Allow the fluid to drain completelv Clean and reinstall the drain plug Torque to 11 ft Ibs 15 Nm Add the recommended fluid See table above for capacity Reinstall the fill plug Torque to 8 10 ft Ibs 11 14 Nm Check for leaks Dispose of used fluid properly Dy ai 75 MAINTENANCE Rear Gearcase Qil Alwavs check an
66. hrottle operation while in the speed limit mode may cause fuel to build in the exhaust resulting in engine popping and or engine damage 59 OPERATION Hauling Cargo AWARNING 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 NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle When determining the weight you are adding to the vehicle include the weight of the operator accessories loads in the rack or box and the load on the trailer tongue The combined weight of these items must not exceed the maximum weight capacity 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 only one rack increases the possibility of vehicle overturn CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE Carrying loads high on the racks raises the center of gravity of the vehicle and creates a less stable operating condition SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered
67. ive gloves 6 Lightly tap on the exhaust pipe with a rubber mallet while repeating step 4 7 Ifparticles 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 8 Place the transmission in PARK Lock the parking brake Repeat steps 4 to 6 until no more particles are expelled 9 Stop the engine Allow the arrestor to cool 10 Reinstall the arrestor plug and remove the exhaust outlet cover or plug 97 MAINTENANCE PVT Svstem AWARNING Failure to comply with the instructions in this warning can result in severe injury or death Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at a high speed The PVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe e Always follow all recommended maintenance procedures See your dealer as outlined in the owner s manual e 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
68. life of the PVT compo nents belt cover etc 99 MAINTENANCE PVT System When To Use Low Range and High Range Condition Range to Use 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 High 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 operat ing 1 2 100 Position the vehicle on a level surface Remove the drain plug Allow the water to drain completelv Rein stall the drain plug Start the engine Place the transmission in PARK Applv varving throttle for 10 15 seconds to expel the moisture and air drv 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 trans mission to the lowest available range Test for belt slippage If the belt slips repeat the process Take the vehicle to vour dealer for service as soon as possible MAINTENANCE Batterv AWARNING 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 AWARNING Battery electrolyte is
69. loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing downhill USE EXTREME CAUTION when operating with loads that extend over the rack sides Stability and maneuverability may be adversely affected causing the vehicle to overturn DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the front rack DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS Vehicle should never exceed 10 mph 16 kph while towing a load on a level 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 60 OPERATION Hauling Cargo Never exceed the weight capac ities specified for vour ATV on warning labels and in the speci fications section of this manual 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 hillv 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 heavv cargo to extend belt life Towing Loads Always attach a towed load to the hitch point Remove
70. lter pump replace lines every two years gt Radiator 100 H 12M 1000 1600 Inspect clean external surfaces gt Cooling hoses 100 H 12M 1000 1600 Inspect for leaks if applicable gt Engine mounts 100 H 12M 1000 1600 Inspect Exhaust muffler 100 H 12M 1000 1600 Inspect pipe E Spark plug 100 H 12M 1000 1600 Inspect replace as needed E gt Wiring 100 H 12M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc 67 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km H 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 H Brake fluid 200 H 24M 2000 3200 Change every two years gt Fuel filter 200 H 24M 2000 3200 Check for leaks around lines B Replace everv 2 vears more E often under extreme conditions Spark arrestor 300 H 36 M 3000 4800 Clean out E Toe adjustment Inspect periodically adjust when parts are replaced Headlight aim Adjust as needed gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service E Have an authorized Polaris dealer perform these services 68 Lubrication Guide Check and lubricate all componen
71. mend 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 USFS standard 5100 1c for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with Polaris recommendations 124 WARRANTV Exported Vehicles EXCEPT WHERE SPECIFICALLV REQUIRED BV LAW THERE IS NO WAR RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCA TION This policy does not apply to vehicles that have received authorization for export from Polaris Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warranty or service bulletin coverage if you have any questions This policy does not apply to vehicles registered to government officials or military per sonnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Recalls How to Get Service In the Country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer If you move or are traveling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any a
72. mpletelv everv two vears and add a fresh mixture of antifreeze and water Replace the coolant anv time the cooling svstem has been drained for maintenance or repair If the recoverv bottle has run drv check the level in the radiator Add coolant as needed CAUTIONI Escaping steam can cause burns Never remove the pressure cap while the engine is warm or hot Alwavs allow the engine to cool before removing the pressure cap 1 Open the front box cover and pull open the access door Remove the pressure cap 3 Using a funnel slowly add coolant through the radiator filler neck 4 Reinstall the pressure cap Use of a non standard pressure cap will not allow the recovery system to function properly Radiat Contact your dealer for the aa correct replacement part 5 Secure the access door 6 Secure the box cover 79 MAINTENANCE Brakes Hand Brake The front and rear brakes are hvdraulic disc brakes activated bv moving the single brake lever toward the handlebar These brakes are self adjusting 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 likelv and the diaphragm should be replaced To ensure proper diaphragm operation alwavs fill the reservoir as needed whenever the cover is loosened or removed Do not overfill WARNING An over full master cylinder may cause brake drag or brake lock up which could res
73. n 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 2 40 Enter the diagnostic mode Toggle to the screen that displays either kilometers KM or miles MP 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 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes The EFI diagnostic mode is for informational purposes only Please see your Polaris dealer for all major repairs See page 43 for Blink Codes and Failure Descriptions Use the follow ing procedure to download blink codes failure codes from the EFI module 1 2 3 4 Place the transmission in PARK Stop the engine Turn the kev switch to the ON position Turn the kev switch off and on three times in less than five seconds then leave the switch on Anv blink code numbers stored in the EFI module will display one at a time on the screen The number 61 and the word END displays after all codes have been transmitted 41 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Code Definitions Open Load There is a break in the wires that lead to the item listed in the chart injector fuel pump etc or the item has faile
74. nation operator error or abuse improper component alignment tension adjustment or altitude compensation failure due to snow water dirt or other foreign substance ingestion contamination improper maintenance modified components use of aftermarket components resulting in failure unauthorized repairs repairs made after the warranty period expires or by an unauthorized repair center use of the product in competition or for commercial purposes Warranty will not apply to any product which has been damaged by abuse accident fire or any other casualty not determined a defect of materials or workmanship 123 WARRANTV LIMITATIONS OF WARRANTIES AND REMEDIES 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 limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not
75. nded safety training before operating this vehicle See page 7 Do not allow anyone under 16 years of age to operate this vehicle Do not allow anyone with cognitive or physical disabilities to oper ate this vehicle Never carry a passenger on this ATV Engine exhaust fumes are poisonous Never start the engine or let it run in an enclosed area Before operating learn how to use the auxiliary brake for emer gency situations if service brakes become inoperable Operate this vehicle off road only Never operate the vehicle on pavement or on any public street road or highway including dirt and gravel roads Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness Clean headlights fre quently and replace burned out headlamps promptly Drive in a manner appropriate for your skills and operating condi tions Never operate at excessive speeds Never attempt wheelies jumps or other stunts Never remove your hands from the handle bars while operating and always keep both feet on the footrests Never consume alcohol or drugs before or while operating an ATV Always use the size and type of tires specified for your vehicle Always maintain proper tire pressure Never operate a damaged ATV After any overturn or accident have a qualified service dealer inspect the entire machine for possible damage Never operate the ATV on a frozen body of water Do not touch hot exhaust s
76. nder certain conditions Always exercise extreme caution whenever handling gasoline e Always refuel with the engine stopped and outdoors or in a well ventilated area e Do not smoke or allow open flames or sparks in or near the area where refu eling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck e If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Never start the engine or let it run in an enclosed area 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 Failure to Inspect Before Operating Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident Always inspect the ATV before each use to make sure it s in safe operating condition Always follow all inspection and maintenance procedures and schedules described in the owner s manual 11 SAFETV Safetv Warnings Protective Apparel Riding in this vehicle without wearing an approved helmet and protective evewear increases the risk of a serious injuries in the event of an accident Operator and passenger must alwavs wear an approved helmet tha
77. needed to raise the specific grav ity to 1 270 or greater 3 Reinstall the battery See page 103 Make sure the positive terminal is toward the front of the vehicle Battery Charging Sealed Battery The following battery charging instructions apply only to the installa tion of a sealed battery Read all instructions before proceeding with the installation of this battery The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Never pry the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage WARNING An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher 2 Ifthe voltage is less than 12 8 volts recharge the battery at 1 2 amps or less until battery voltage is 12 8 or greater 3 When using an automatic charger refer to the charger manufac turer s instructions for recharging When using a constant current charger use the g
78. ngine Pings or Knocks Possible Cause Poor qualitv or low octane fuel Solution Replace with recommended fuel Incorrect ignition timing See vour dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Runs Irregulariv Stalls or Misfires Possible Cause Fouled or defective spark plugs Solution Inspect clean and or replace spark plugs Worn or defective spark plug wires See vour dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low batterv voltage Recharge batterv to 12 8 VDC Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Reverse speed limiter malfunction Inspect and clean or replace See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure Possible Lean Fuel Cause Low or contaminated fuel See your dealer Solution Add or change fuel clean the fuel system Kinked or plugged fuel tank vent line Inspect and replace Low octane fuel Replace with recommended fuel Clogged fuel filter Replace filter Incorrect fuel Possible Rich Fuel Cause Fuel is very high octane Replace with recommended fuel Solution Replace with lo
79. o conduct this maintenance will not void the emissions warranty but may affect emissions m Have an authorized Polaris dealer perform these services 65 MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km E Steering Pre Ride Make adjustments as need ed See Pre Ride Checklist gt Front suspension Pre Ride on page 46 gt Rear suspension Pre Ride Tires Pre Ride gt Brake fluid level Pre Ride gt Brake lever travel Pre Ride Brake system Pre Ride Wheels fasteners Pre Ride Frame fasteners Pre Ride gt Engine oil level Pre Ride gt Air filter pre filter Daily Inspect clean often replace E as needed gt Air box sediment Daily Drain deposits when visible tube Coolant Daily Check level daily change if applicable coolant every 2 years Headlamp taillight Daily Check operation apply dielectric grease if replacing gt Air filter Weekly Inspect replace as needed E main element Recoil housing Weekly Drain water as needed if applicable check often if operating in wet conditions gt Brake pad wear 10H Monthly 100 160 Inspect periodically LI Batterv 20H Monthiv 200 320 JCheck terminals cle
80. oid the use of automotive products some of which can scratch the finish of your vehicle e Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 108 MAINTENANCE Cleaning and Storage Chrome Wheel Care if equipped Proper maintenance will protect chrome wheels from corrosion pre serve wheel life and ensure a like new appearance for many years 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 polish 4 Routinely and liberally apply a weather resistant wax to each pol ished 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 out lined above 109 MAINTENANCE Cleaning and S
81. ontrol 122 WARRANTV LIMITATIONS OF WARRANTIES AND REMEDIES Warranty does not apply to parts exposed to friction surfaces stresses environmental conditions and or contamination for which they were not designed or not intended including but not limited to the following items e Wheels and tires e Finished and unfinished surfaces e Suspension components e Carburetor Throttle body components e Brake components Engine components Seat components Drive belts e Clutches and components e Hydraulic components Steering components Circuit breakers Fuses e Batteries Electronic components e Light bulbs Sealed beam lamps Warranty applies to the product only and does not allow for coverage of personal loss Some items are considered consumable meaning they are considered part of normal maintenance or part of completing an effective repair The following items are excluded from warranty coverage in the event of a warranty claim e Spark Plugs e Lubricants such as oil grease etc e Filters Batteries unless defective e Fuel Cosmetic damage repair Sealants Coolants e Hotel fees e Meals e Towing charges Shipping handling fees e Mileage e Product pick up delivery e Rentals Loss of product use e Loss of vacation personal time This warranty also excludes failures resulting from improper lubrication improper engine timing improper fuel surface imperfections caused by external stress heat cold or contami
82. place during operation 98 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 cen trifugal force decreases 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 km h due to the system s dependence on engine speed For example when operating at a ground speed of 3 MPH 5 km h 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 km h 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 wears clutch components and causes outer clutch covers to fail The air temperature in the clutch cover is substantially reduced by using low range while operating at low ground speeds Reducing the tempera ture inside the clutch cover greatly extends the
83. power outlets provide 12 volt power for operating accesso ries Accessory outlets are available for all models Polaris also has a wide range of additional accessories available for your ATV Always install accessories that are approved for ATV use Please see your Polaris dealer 112 MAINTENANCE Transporting the Vehicle Follow these procedures when transporting the vehicle 1 Stop the engine 2 Place the transmission in PARK 3 Lock the parking brake 4 Secure the fuel cap oil cap and seat AROS E Sy f deg TIT p OF Boo r H LEa taw kol 5 Always tie the frame of the ATV to the transporting unit securelv with suitable g 3 straps or rope Do not K A attach tie straps to the front A arm bolt pockets racks or handlebars 6 Remove the key to prevent loss during transporting 113 TROUBLESHOOTING Drive Belt Wear Burn Possible Cause Driving onto a pickup or tall trailer in high range Solution Use low range during loading Starting out going up a steep incline Use low range or turn around using the K turn see page 56 Driving at low RPM or ground speed 3 7 MPH Drive ata higher speed or use low range more frequentiv See page 100 Insufficient warm up at low ambient tempera tures Warm the engine at least 5 minutes With the transmission in neutral advance the throttle to about 1 8 throttle in short bursts 5 to 7 times The belt will
84. pward or downward 1 Loosen the phillips screw located at the rear of the headlamp 2 Tilt the headlamp upward or downward 3 Tighten the screw MAINTENANCE Phillips Screw ET IL L EPI SDG N OS NA lt gt o fN 91 MAINTENANCE Lights Headlight Housing Replacement 1 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 3 Lift the pod cover and disconnect the speedometer harnesses from the speedometer 4 Unplug the headlamp from the wiring harness 5 Use a small screwdriver to remove the o rings from the headlight mounting tabs 6 Pull the headlight housing up to release it from the locking tabs 7 Lift the adjusting knob up to remove it from the locking tabs 8 Carefully pull the assembly up and out of the pod 9 Reverse the steps to install the new housing and reassemble the pod The distance from the headlamp parting line to the end of the adjustment knob stop is 5 1 8 13 cm 10 Adjust the headlight aim by turning the adjusting knob 92 MAINTENANCE Lights Lower Headlamp Replacement 1 Turn the back of the headlight harness counter clockwise and pull the harness assembly away from the headlight assembly 2 Remove the headlamp and install the new headlamp 3 Reinstall the harness assembly into the headlight assembly
85. ral times while driving slowly The friction will help dry out the pads If it s unavoidable to enter water deeper than the footrest level e Proceed slowly Avoid rocks and obstacles e Balance your weight carefully Avoid sudden movements e Maintain a steady rate of speed Do not make sudden turns or stops Do not make sudden throttle changes 57 OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles 1 2 58 Alwavs check for obstacles before operating in a new area Look ahead and learn to read the terrain Be constantiv alert for haz ards such as logs rocks and low hanging branches Travel slowlv and use extra caution when operating on unfamiliar terrain Not all obstacles are immediatelv visible Never attempt to operate over large obstacles such as rocks or fallen trees OPERATION Driving in Reverse Follow these precautions when operating in reverse Sa d Alwavs check for obstacles or people behind the vehicle Always avoid backing downhill Back slowly Apply the brakes lightly for stopping Avoid turning at sharp angles Never open the throttle suddenly Do not use the override button unless additional wheel speed is required for vehicle movement Use the override with caution as rearward vehicle speed is greatly increased Do not operate at wide open throttle Operate the throttle just enough to maintain a desired speed NOTICE Excessive t
86. rk consists of a circle surrounding the letter E followed by the distinguishing number of the country which has 051039 granted approval The approval number and serial 0006 31 number will also be displayed on the label SAFETV Safe Riding Gear Eve Protection Do not depend on eveglasses or sunglasses for eve protection When ever riding a Polaris vehicle alwavs 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 eve wear is kept clean Gloves Off road style gloves with knuckle pads are the best for comfort and protection Boots The best footwear is a pair of sturdy over the calf boots with low heels 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 Equipment Modifications 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 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 The addition of certain accessories including but not limited to mow ers blades tires
87. rnings Operating Improperlv in Reverse Improperiv operating in reverse could result in a collision with an obstacle or person Alwavs follow proper operating procedures as outlined in this manual See page 59 Before shifting into reverse gear alwavs check for obstacles or people behind the ATV When it s safe to proceed back slowly Improper Tire Maintenance Operating this ATV with improper tires or with improper or uneven tire pressure could cause loss of control or accident Always use the size and type of tires specified for your ATV Always maintain proper tire pressure as described in the owner s manual and on safety labels 18 SAFETV Safetv Warnings Operating Over Obstacles Improperly operating over obstacles could cause loss of control or overturn Before operating in a new area check for obstacles Avoid operating over large obstacles such as rocks and fallen trees If unavoidable use extreme caution and always follow proper operating procedures as outlined in this manual See page 58 Skidding or Sliding Skidding or sliding can cause loss of control or overturn if tires regain traction unexpectedly On slippery surfaces such as ice or loose gravel travel slowly and use extra caution to reduce the chance of skidding or sliding Do not operate on excessively slippery surfaces Operating Through Deep Water Operating the ATV through deep or fast flowing water could cause the tires to float causin
88. s of control avoid sudden braking or sharp turns 7175550 22 SAFETV Safetv Labels and Locations General Warning Discretionarv Warning Tire Pressure Load Warning Tire Pressure Load Warning WARNING Improper tire pressure or overloading can cause loss of control Loss of control can result in severe injurv or death e Cold tire pressure Front 5 0 psi 34 5 kPa Rear 5 0 psi 34 5 kPa e Maximum weight capacity 515 Ibs 234 kg 7175643 23 SAFETV Safetv Labels and Locations Rack Age 16 Warning Warning Warning Clutch Cover Warning No Passenger Warning WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH 7175378 Age 16 Warning WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death NEVER operate this ATV if you are under age 16 7175551 24 SAFETV Safetv Labels and Locations Clutch Cover Warning WARNING e Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed s Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death NO STEP 7172563 Rack Warning Front and Rear WARNING e DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death
89. sprayers or large racks may change the handling char acteristics of the vehicle Use only Polaris approved accessories and familiarize yourself with their function and effect on the vehicle SAFETV Failure to operate the ATV properly can result in a collision loss of control accident or overturn which may result in serious injury or death Heed all safety warnings outlined in this section of the owner s manual See the OPERATION section of the owner s manual for proper operating procedures Operating Without Instruction Operating this ATV without proper instruction increases the risk of an accident The operator must understand how to operate the ATV properly in different situations and on different types of terrain Beginning and inexperienced operators should complete the recommended safety training before operating this vehicle See page 7 Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age 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 10 SAFETV Safetv Warnings Handling Gasoline Gasoline is highly flammable and explosive u
90. t 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 e Do not use a power washer to clean the vehicle e Do not use medium to heavy duty compounds on the finish e Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 107 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 follow ing items e Wheel bearings e Electrical components e Radiator e Switches and controls e Transmission seals Fuel system components e Cab and body panels e Labels and decals If an informational or graphic label becomes illegible or comes off con tact your Polaris dealer to purchase a replacement Replacement safety labels are provided by Polaris at no charge 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 Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle Follow the instructions on the container Polishing Tips e Av
91. t fits properlv and eve protection goggles or face shield Using Alcohol or Drugs Operating the ATV after consuming alcohol or drugs could adverselv affect operator judgment reaction time balance and perception Never consume alcohol or drugs before or while operating an ATV Carrving a Passenger Carrying a passenger greatly reduces the operator s ability to balance and control the ATV which may result in an accident or overturn Never carry a passenger on this ATV 12 Safetv Warnings Operating on Pavement Operating an ATV on paved surfaces including sidewalks paths parking lots and drivewavs mav adverselv affect the handling of the ATV and could result in loss of control and accident or overturn Avoid operating the ATV on pavement ATV tires are designed for off road use If it s unavoidable travel slowly and avoid sudden turns or stops Operating on Public Roads Operating this ATV on public streets roads or highways could result in a collision with another vehicle Never operate the ATV on any public street road or highway including dirt and gravel roads In many states it s unlawful to operate ATVs on public streets roads and highways Operating at Excessive Speeds Operating the ATV at excessive speeds increases the operator s risk of losing control Always operate at a speed that s appropriate for the terrain the visibility and operating conditions and your experience
92. the engine If necessary repeat the drying proce dure 3 4 Turn the engine over several times using the electric start 5 6 7 Take the ATV to your dealer for service as soon as possible whether you succeed in starting it or not 8 If water has been ingested into the PVT follow the procedure on page 100 for drying out the PVT 96 MAINTENANCE Spark Arrestor AWARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death Never run the engine in an enclosed area Remove any combustible materials from the area Wear eye protection and leather work gloves Do not stand behind or in front of the vehicle while purging Never go under the vehicle while it s inclined The exhaust system can get extremely hot Do not perform service on the spark arrestor while the system is hot Allow components to cool sufficiently before proceeding Use the following procedure to periodically purge accumulated carbon from the exhaust pipe muffler 1 Remove the arrestor clean out plug from the bottom of the muffler Be sure to clean out both arrestors if your model Exhaust gt has two Outlet 2 Wy 2 Place the transmission in 0 PARK n l Out PI 3 Start the engine Clean Out Plug 4 Quickly squeeze and release the throttle lever several times to purge carbon from the system 5 Ifcarbon comes out of the exhaust cover or plug the exhaust outlet Wear protect
93. tion 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 ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your ATV is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any ATV that has been altered structurally modified neglected improperly maintained used for 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 unauthorized parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the ATV due to fire explosions or any other cause beyond Polaris c
94. tor Short to Ground 51 Injector Circuit Malfunction Cyl 1 Open Load Short to Ground 51 Injector Circuit Malfunction Cyl 1 Shorted Load Short to Battery 52 Injector Circuit Malfunction Cyl 2 Open Load Short to Ground 52 Injector Circuit Malfunction Cyl 2 Shorted Load Short to Battery 55 MIL Circuit Open Load Short to Ground 55 MIL Circuit Shorted Load Short to Battery 56 Fuel Pump Open Load Short to Ground 56 Fuel Pump Shorted Load Short to Battery 58 Fan Circuit Open Load Short to Ground 58 Fan Circuit Shorted Load Short to Battery 63 Starter Enable Open Load Short to Ground 63 Starter Enable Shorted Load Short to Battery 72 Gear Sensor Signal 73 4X4 Open Load Short to Ground 73 4X4 Shorted Load Short to Battery 74 Rear Differential Enable Open Load Short to Ground if equipped 74 Rear Differential Enable Shorted Load Short to Battery if equipped 61 END SEQUENCE 43 OPERATION Failure to operate the ATV properly can result in a collision loss of control accident or overturn which may result in serious injury or death Read and understand all safety warnings outlined in the safety section of this owner s manual 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 proce dures for a proper break in Careful treatment of a new
95. torage Storage Tips NOTICE Starting the engine during the storage period will disturb the protective film created bv fogging and damage could occur Never start the engine during the storage period Clean the Exterior Make any necessary repairs and then clean the vehicle as recommended See page 107 Stabilize the Fuel 1 Fill the fuel tank 2 Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer Follow the instructions on the container for the recommended amount 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 entire fuel delivery system Oil and Filter Change the oil and filter See page 71 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 110 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the following fluid levels Change fluids as recommended in the Periodic Maintenance Chart beginning on page 64 e Demand drive unit front gearcase Rear gearcase Transmission Brake fluid change every two years and any time the fluid looks dark or contaminated Coolant test strength Fog the Engine 1 Treat the fuel svstem with Polaris Carbon Clean following the instructions on the can Run the engine for
96. ts at the intervals outlined in the Peri odic Maintenance Chart beginning on page 64 Items not listed in the chart should be lubricated at the General Lubrication interval The a arms and lower control arms are lubricated at the factorv and no additional lubrication will be needed However if these components are subjected to severe use grease zerks have been provided for additional lubrication at the user s discretion MAINTENANCE Oil GL5 80 90 weight gear lube Item Lube Capacity at Inspection Fluid Change Procedure Engine Oil PS 4 PLUS Performance 2 qt 1 9 I See page 70 Synthetic 2W 50 Brake Fluid DOT 4 Only See page 30 Transmission Oil Polaris AGL Synthetic 15 oz 450 ml See page 73 Gearcase Lube Demand Drive JDemand Drive Plus Fluid 9 oz 265 ml See page 74 Fluid Front Gearcase Rear Gearcase ATV Angle Drive Fluid or 5 oz 150 ml See page 76 Front Prop Shaft Yoke Polaris Premium U Joint Lube Grease fittings 3 pumps maximum every 500 miles before long periods of storage or after pressure washing or submerging Front Prop Shaft Yoke 69 MAINTENANCE Engine Oil Oil Recommendations Polaris recommends the use of Polaris PS 4 PLUS Performance Svn thetic 2W 50 4 cycle oil or a similar oil for this engine Oil may need to be changed more frequently if Polaris oil is not used Always use 2W 50 oil Follow the manufacturer s recommendations
97. ty 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 1 888 704 5290 Canada 1 204 925 7100 126 WARRANTV U S A EPA Emissions Limited Warrantv This emissions limited warranty is in addition to the Polaris standard limited warranty for your vehicle Polaris Industries Inc warrants that at the time it is first purchased this emissions certified vehicle is designed built and equipped so it conforms with applica ble U S Environmental Protection Agency emission regulations Polaris warrants that the vehicle is free from defects in materials and workmanship that would cause it to fail to meet these regulations The warranty period for this emissions certified vehicle starts on the date the vehicle is first purchased and continues for a period of 500 hours of engine operation 5000 kilo meters 3100 miles of vehicle travel or 30 calendar months from the date of purchase whichever comes first This emissions limited warranty covers components whose failure increases the vehi cle s regulated emissions and it covers components of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this war ranty is the responsibility of the vehicle owner This
98. uidelines on the next page for recharging 105 MAINTENANCE Batterv Batterv Charging Sealed Batterv Always verify battery condition before and 1 2 hours after the end of charging State of 3 Charge Time Voltage Action Using constant current Charge charger standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 None required mos from date of manufacture 75 100 12 5 12 8 volts May need slight 3 6 hours charge if no charge given check in 3 months Needs charge 5 11 hours 50 75 12 0 12 5 volts 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At least 20 hours 106 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components NOTICE High water pressure may damage components Polaris recommends washing the vehicle by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage plastic surfaces Do not allow these types of products to contact 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 las
99. ult in serious injury or death Maintain brake fluid at the recommended level Do not overfill 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 1 Always keep brake fluid at an adequate level See page 30 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 Replace brake pads when they are worn to 3 64 1 mm 5 Check the security and surface condition 3 64 1 mm of the disc Auxiliary Foot Brake The hydraulic auxiliary brake system requires no adjustment Check the brake fluid level frequently for the auxiliary brake system See page 32 80 Toe Alignment MAINTENANCE 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 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 1 Position the vehicle on a level surface 2 Place the handlebars ina straight ahead position 3 Tie a length of string between two stands as shown in the illustration Position the stands so that the string is flush with the side of the rear tire If available you may use a long straight e
100. ure the battery hold down strap Verify that cables are properly routed Cables should be safely tucked away at the front and rear of the battery 103 MAINTENANCE Batterv Batterv Storage Whenever the vehicle is not used for a period of three months or more remove the batterv from the vehicle ensure that it s fullv 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 Polaris recommends maintaining batterv charge bv using a Polaris Bat terv Tender charger or bv charging about once a month to make up for normal self discharge Batterv Tender can be left connected during the storage period and will automaticallv charge the batterv if the voltage drops below a pre determined point See page 120 for the part numbers of Polaris products Batterv Fluid Conventional Batterv A poorlv maintained batterv will deteriorate rapidly Check the battery reed hee fluid level often Maintain the fluid level between the upper and lower level marks Add only distilled water Tap water contains minerals that are harmful to a battery 104 MAINTENANCE Batterv Batterv Charging Conventional Batterv 1 Remove the battery from the vehicle to prevent damage from leak ing or spilled electrolyte during charging See page 102 2 Charge the battery with a charging output no larger than 1 10 of the battery s amp hr rating Charge as
101. uthorized 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 125 WARRANTV Exported Vehicles How to Get Service If Purchased From A Private Partv If you purchase a Polaris product from a private citizen to be kept and used outside of the country in which the vehicle was originally purchased all warranty coverage will be denied Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ran
102. vour Polaris dealer Record maintenance and service in the Maintenance Log beginning on page 129 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 e Frequent immersion in mud water or sand e Racing or race style high RPM use e Prolonged low speed heavy load operation e Extended idle Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crank case 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 64 MAINTENANCE Periodic Maintenance Chart AWARNING Improperly performing the procedures marked with a could result in component failure and cause an accident which may result in serious injury or death Always have an authorized Polaris dealer perform these services Maintenance Chart Key gt Perform these operations more often for vehicles subjected to severe use E Emission related service Failure t
103. wer octane fuel Stopping starting without adequate warm up Allow engine to warm up before operat ing and or stopping Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace 116 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Solution Refuel cycle key to ON position three times for 5 seconds each then start Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Fouled or defective spark plugs Inspect clean and or replace spark plug Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure See your dealer Overheated engine Clean radiator screen and core clean engine exterior see your dealer Engine Overheating Possible Cause Debris lodged in screen Solution Remove and clean the screen Pull on the top portion of the screen then remove the lower portion
104. when braking while traveling down hill See page 55 Always descend a hill with the transmission in forward gear Do not descend a hill with the transmission in neutral e Always check the terrain carefully before descending a hill Shift your weight rearward e Never travel down a hill at high speed e 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 Crossing Hillsides Driving on a sidehill is not recommended Improper procedure could cause loss of control or overturn Avoid crossing the side of any hill unless absolutely necessary If crossing a hillside is unavoidable always follow proper procedures as described in the owner s manual See page 54 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 56 15 SAFETV Safetv Warnings Stalling While Climbing a Hill Stalling rolling backwards or improperly dismounting while climbing a hill could cause an overturn e Always maintain a steady speed when climbing a hill If all forward speed is lost e Keep body weight uphill e Apply the brakes e Lock the parking brake when fully stopped e Dismount on uphill side or to either side if ATV is pointed straight uphill e Turn the ATV around and remount following the procedure described in the owner s manu
105. y placing a suitable stand under the footrest frame 6 Remove the wheel nuts 7 Remove the wheel 85 MAINTENANCE Tires Wheel Installation 1 Place the transmission in PARK Lock the parking brake 3 Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation 4 Install the wheel nuts and finger tighten them 5 Lower the vehicle to the ground 6 Torque the wheel nuts to specification WARNING Loose nuts could cause a tire to come off during operation which could result in an accident or overturn Always ensure that all nuts are torqued to specification 90 ft Ibs 122 Nm 27 ft Ibs 37 Nm Cast Aluminum Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loos ened for maintenance service Nut Type Nut Torque Lug Nut 90 ft Ibs 122 Nm 2 Piece Flange Nut 27 ft lbs 37 Nm 86 MAINTENANCE Air Filter 1 Remove the seat Pre Filter 2 Release the air box cover clips and remove the air box cover Main Filter 3 Loosen the clamp and remove the filter 4 Remove the fabric type pre filter from the main filter Wash the pre filter in soapy water then rinse and let dry Reinstall the pre filter over the main filter Install a new main filter if needed Reinstall the filter into the air box and tighten the clamp Do not over tighten the clamp as
106. ystem components Always keep com bustible materials away from the exhaust system Always remove the ignition key when the vehicle is not in use to prevent unauthorized use 47 OPERATION Know Your Riding Area Tread Lightly Familiarize yourself with all laws and regulations concerning the opera tion of this off road vehicle in your area Respect the environment in which you ride Find out where the designated riding areas are by con tacting your Polaris dealer a local riding club or local officials Help keep our trails open for recreational vehicle use As an off road enthusiast you represent the sport and can set a good example or a poor example for others to follow Tread lightly Operate with respect for the terrain avoid littering and always stay on the designated trails Trail Etiquette Always practice good etiquette when riding Allow a safe distance between your vehicle and other vehicles operating in the same area Communicate to oncoming operators by signaling the number of vehi cles in your group When stopping move your vehicle to the edge of the trail as far as possible to allow others to pass safely 48 OPERATION Starting the Engine 1 Position the vehicle on a level surface outdoors or in a well venti lated area 2 Place the transmission in PARK 3 Lock the parking brake Tip The starter interlock will prevent the engine from starting if the transmission is in gear and the brake is not engaged

Polaris 9922079 Offroad Vehicle User Manual

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