Home

Polaris 9920775 Offroad Vehicle User Manual

1. 21 SAFETV Operator Safetv A WARNING POTENTIAL HAZARD Operating the ATV after consuming alcohol or drugs WHAT CAN HAPPEN Consumption of alcohol and or drugs could seriousiv affect operator judgment Reaction time mav be slower and operator balance and perception could be affected Consuming alcohol and or drugs before or while operating an ATV could result in an accident causing severe injurv or death HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while operating an ATV A WARNING POTENTIAL HAZARD Operating the ATV at excessive speeds WE WHAT CAN HAPPEN to NI a A i f Kic Excessive speed increases the t A a operator s chance of losing control of dem N L the ATV which can result in an j 7 f accident causing severe injury or a OY death O HOW TO AVOID THE HAZARD Sa Always operate the ATV at a speed that s proper for the terrain visibility and operating conditions and your experience 22 Operator Safetv SAFETV A WARNING POTENTIAL HAZARD Attempting jumps and other stunts WHAT CAN HAPPEN Attempting stunts increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt jumps or other stunts Avoid exhibition driving A WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properlv maintain the ATV WHAT CAN HAPPEN Poor maintenance increases
2. 37 38 Brake Front Wheel 85 Brake Middle Axle 85 Brake Parking 39 Brake Reat s i2 4 ib noha ans os 85 Brakelight 95 Brakes nerti Ka ATS 85 Break In Period 51 Breather Filter 91 c Camber Adjustment 115 Carburetor 0 0 119 Carburetor Adjustment 119 Cargo ata e A 55 57 Cargo Capacities 55 Caster Adjustment 115 Cleaning and Storage 109 113 Clothing iskart wade 11 Clutching Chart 125 Consumer Product Safetv 17 Coolant Bottle 83 Coolant Radiator 84 Cooling System 83 84 Crankcase Emission Control System 69 D Drive Belt Wear Burn 120 Drive Chain Front 117 Drive Chain Rear Axle 118 Drivetrain Break In 51 Driving Down ill 63 Driving in Reverse 67 Driving on a Sidehill 62 Driving on Slipperv Surfaces 60 Driving Over Obstacles 66 140 D Driving Procedures 58 Driving Safelv 58 68 Driving Through Water 65 Driving Uphill 000 61 Dumping Cargo 56 E Electromagnetic Interference 69 Emissions Limited Warrantv 136 Engaging AWD 43 Engine Break In 51 Engine Fogging 111 Engine Idle RPM
3. HOW TO AVOID THE HAZARD Before shifting into reverse gear always check for obstacles or people behind the ATV When it s safe to proceed back slowly 30 SAFETV Operator Safetv A WARNING POTENTIAL HAZARD A Operating this ATV with improper tires or with improper or uneven tire rere pressure B o WHAT CAN HAPPEN Use of improper tires or operation of the ATV with improper or uneven tire pressure could cause loss of control or accident HOW TO AVOID THE HAZARD Alwavs use the size and tvpe of tires specified for the ATV in the owner s manual Always maintain proper tire pressure as described in the owner s manual and on safety decals A WARNING POTENTIAL HAZARD Operating the ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of the ATV may cause changes in handling which could lead to an accident HOW TO AVOID THE HAZARD Never modify the ATV through improper installation or use of accessories All parts and accessories added to the vehicle must be genuine Polaris Industries Inc or equivalent components designed for use on this ATV and should be installed and used according to approved instructions See your authorized Polaris ATV dealer for more information 31 SAFETV Operator Safetv A WARNING POTENTIAL HAZARD Overloading the ATV or carrving towing cargo improperly WHAT CAN HAPPEN Overloading and
4. See vour dealer Incorrect ignition timing See vour dealer Mechanical failure See your dealer Loose ignition connections Check all connections and tighten Water present in fuel Replace with fresh recommended fuel 121 TROUBLESHOOTING Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Runs Irregularly Stalls or Misfires Possible Cause Solution Fouled or defective spark plug s Inspect clean and or replace spark plug s Worn or defective spark plug wires See your 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 battery voltage Recharge battery to 12 8 VDC Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with 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 Possible Lean Fuel Cause Low or contaminated fuel See your dealer Solution Add or change fuel clean the fuel sy
5. Ground Clearance 5 5 in 14 cm Dry Weight 895 Ibs 406 kg Minimum Turning Radius 119 in 302 cm unloaded Engine EHS50PLE104 Displacement 499 cc Bore x Stroke 92 x 75 mm Alternator Output 250W 5000 RPM Compression Ratio 10 2 1 Starting System Electric w recoil backup Carburetor BST 34 Pilot Jet 40 Main Jet 142 5 Needle Jet Q 4M 829 Jet Needle 4HB41 3 Ignition System DC CDI Ignition Timing 30 2 BTDC 5000 RPM Spark Plug Gap NGK BKRSE 0 036 9 mm Lubrication System Dry Sump Driving System Type Automatic PVT Polaris Variable Transmission Front Suspension MacPherson strut with 6 7 17 cm travel Rear Suspension Progressive rate with 7 5 19 cm travel Based on EU Directive 76 432 EC 124 SPECIFICATIONS Sportsman 500 6X6 Transmission Automatic PVT H L N R Gear Reduction Low 6 69 1 Gear Reduction Reverse 5 17 1 Gear Reduction Forward 3 34 1 Drive Ratio Front 2 1 Drive Ratio Final 12 38 80P Tires Pressure Front Polaris PXT 25x8 12 5 psi Tires Pressure Center Polaris PXT 25x11 10 5 psi Tires Pressure Rear Polaris PXT 25x11 10 5 psi Brakes Front Hydraulic Disc Brakes Rear Hydraulic Disc Brake Auxiliary Hydraulic Disc Brake Parking Hydraulic lock all wheel Headlight 1 Single Beam on Handlebar 50 watt 2 Single Beam on Gri
6. Never attempt to operate over large obstacles such as rocks or fallen trees Alwavs follow proper procedures when operating over obstacles as described in this manual Always be careful of skidding or sliding On slippery surfaces like ice travel slowly and use extra caution to reduce the chance of skid ding or sliding out of control Avoid operating the ATV through deep or fast flowing water If it s unavoidable travel slowly balance your weight carefully avoid sud den movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Test the brakes after leaving water If necessary apply them lightly several times to allow friction to dry out the pads Always check for obstacles or people behind the ATV before operat ing in reverse When it s safe to proceed in reverse move slowly and avoid turning at sharp angles Always use the size and type of tires specified for your ATV and always maintain proper tire pressure Never modify an ATV through improper installation or use of acces sories Never exceed the stated load capacity for your ATV Cargo must be properly distributed and securely attached Reduce speed and follow the instructions in this manual for carrying cargo or towing Allow a greater distance for braking Always remove the ignition key when the vehicle is not in use to pre vent unauthorized u
7. 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 130 WARRANTV Exported Vehicles How to Get Service If Purchased From A Private Partv If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased all warranty coverage will be denied Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ranty or service bulletin coverage of any kind Vehicles registered to Government offi cials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions call Polaris Customer Assistance United States 1 763 417 8650 Canada 1 204 925 7100 131 WARRANTV California Emission Control Warrantv Statement Vour Warrantv Rights and Obligations The California Air Resources Board and Polaris Industries Inc 2100 Highwav 55 Medina Minnesota 55340 herein POLARIS are pleased to explain the emission con trol system warranty on your 2006 and later Large Spark Ignition Engine herein LSI engine The California Air Resources Board has designated this
8. connection between the oil tank and pump inlet has been disconnected 1 Clamp or pinch off the vent line approximately 2 5 cm from the oil tank between the end of the oil tank vent fitting and the vent line s pressure relief slit 2 Start the engine Allow it to idle for 45 60 seconds 3 Remove the vent line clamp If the line is bled properly you should hear a rush of air indicating that the line is properly primed and ready for operation Pressure Relief Slit NOTE If you do not hear air the line has not bled Repeat the priming proce dure 80 MAINTENANCE Transmission Oil Alwavs check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 70 Maintain the oil level at the bottom of the fill plug hole threads We recommend the use of Polaris Premium AGL Svnthetic Gearcase Lubricant See page 126 for the part numbers of Polaris products Access the transmission fill plug from the right side of the vehicle Access the drain plug from the left side of the vehicle Oil Check 1 Position the vehicle on a level sur face 2 Remove the propshaft shield from the right side of the vehicle 3 Remove the fill plug 4 Check the oil level Add the recom mended gearcase oil as needed to bring the level to the bottom of the fill hole threads 5 Reinstall the fill plug Torque to 14 ft Ibs 19 Nm 6 Reinstall the propshaft shield Oil Cha
9. never back it down the hilll Use the K turn to turn around 64 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 Staving uphill of the vehicle turn the handlebars full left While holding the service brake release the parking brake lock and slowlv allow the vehicle to roll around to vour right until it s point ing across the hill or slightly downward Lock the parking brake Remount the vehicle from the uphill side keeping body weight uphill Start 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 Safelv 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 crossing 2 Choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles 4 After crossing dry the brakes by applying light pressure to the lever until braking action is normal After running the vehicle in water it s critical to have it serviced as out lined in the maintenance chart See page 70
10. 34 Nm 9 Reattach the oil line 10 Place shop towels beneath the oil filter Using an oil filter wrench turn the filter counter clockwise to remove it 11 Using a clean dry cloth clean the filter sealing surface on the crankcase 12 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 13 Install the new filter and rotate it clockwise by hand until the filter gasket contacts the sealing surface then turn it an additional 1 2 turn 14 Approximately one cup of engine oil will remain in the crankcase To drain remove the drain plug on the lower right side of the crank case NOTE The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches 15 Reinstall the drain plug Torque to 14 ft Ibs 19 Nm 16 Remove the dipstick Add two quarts 1 9 1 of recommended oil Reinstall the dipstick NOTE Ifthe sump is not drained add about 1 3 4 quarts 1 6 I initially 17 Place the transmission in neutral 18 Lock the parking brake 19 Prime the oil pump using the procedure on page 80 Then stop the engine and inspect for leaks 20 Check the oil level Add oil as needed to bring the level to the upper mark on the dipstick 21 Dispose of used filter and oil properly 79 MAINTENANCE Oil and Filter Change Oil Pump Priming This priming procedure must be performed whenever the oil hose
11. Avoid crossing the side of a steep hill When crossing the side of a hill Always follow proper procedures as described in the owner s manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV 27 SAFETV Operator Safetv A WARNING POTENTIAL HAZARD Stalling rolling backwards or improperly dismounting while climbing ma a hill l WHAT CAN HAPPEN The vehicle could overturn HOW TO AVOID THE HAZARD Maintain steadv speed when climbing a hill If all forward speed is lost Keep your weight uphill Apply the service brakes Lock the parking brake when fully stopped Never back down a hill If the ATV begins rolling backwards Keep weight uphill Never apply engine power Never apply the rear brake while rolling backwards Apply the service brake gradually When fully stopped apply the rear brake as well and then lock the parking brake Dismount on uphill side or to either side if ATV is pointed straight uphill Turn the ATV around and remount following the procedure described in the owner s manual See page 64 28 SAFETV Operator Safetv A WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Avoid operating over large obstacles such as roc
12. Cargo Load Distribution Load cargo as far forward as possible 1 Never exceed the maximum capacities for hauling cargo as stated on the load distribution warning labels and on page 55 2 Always load the cargo box with the load as far forward as possible 3 Always operate the vehicle with extreme caution whenever hauling or towing loads Balance handling and control may be affected Slow down 5 The cargo box dump latch must be securely latched before loading and operating Unintentional box tilting will result if weight is placed in the rear of the box and the latch is not secured 4 WARNING Operating with the cargo box in the raised position can cause serious injury and damage to the vehicle The cargo box could close unexpectedly and injure the driver The rear tires will also catch the rear of the box damaging the vehicle and creating hazardous driving conditions Never operate this vehicle with the cargo box in the raised position 57 OPERATION Driving Safelv Driving Procedures D BOTS AON i E 58 Wear protective riding gear See page 10 Sit upright with both feet on the footrests and both hands on the handlebars Start the engine and allow it to warm up See page 53 Shift the transmission into gear Check your surroundings and determine your path of travel Release the parking brake Slowly depress the throttle with your right thumb and begin driving Dri
13. HAZARD Operating an ATV on paved surfaces including sidewalks paths parking lots and driveways WHAT CAN HAPPEN ATV tires are designed for off road use Operating on paved surfaces may adversely affect the handling of the ATV and could result in loss of control accident and or injury HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement If it s unavoidable travel slowly and avoid sudden turns or stops 20 SAFETV Operator Safetv A WARNING POTENTIAL HAZARD Operating this ATV on public streets roads or highwavs WHAT CAN HAPPEN The ATV could collide with another vehicle HOW TO AVOID THE HAZARD Never operate the ATV on anv public street road or highway including dirt and gravel roads In manv states it s illegal to operate ATVs on public streets roads and highwavs A WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet eve protection and protective clothing WHAT CAN HAPPEN Operating an ATV without an approved helmet increases the risk of a severe head injurv or death in the event ofan accident Operating without eve protection could result in an accident and could increase the chance of a severe injurv in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved helmet that fits properly Alwavs wear eve protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants
14. Place your hand on top of the side panel behind the fuel tank With a quick and firm motion push down on the side panel to disengage the top rear two tabs Then pull up on side panel to disengage front upper and lower tabs 4 To reinstall the side panel align the panel tabs with the slots on the front cab Push the panel upward and for ward until the tabs lock Bend the rear of the side panel and insert the two tabs into the rear cab Step 2 87 MAINTENANCE Tires Refer to the specifications section beginning on page 124 for recom mended tire tvpe size and pressure A WARNING Operating your ATV with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death Maintain proper tire pressure as described on the decal on your ATV and in the owner s manual Always use original equipment size and type when replacing tires Make sure the wheels are installed properly Always replace tires when the tread depth measures 1 8 3 mm or less Tire Tread Depth Always replace tires 1 8 3 mm t when tread depth is worn to 1 8 3 mm or less tp SS Wheel Removal Stop the engine Place the transmission in gear Lock the parking brake Loosen the wheel nuts slightly oe Sete Aa Elevate the side of the vehicle by placing a suitable stand under the footrest frame 6
15. Remove the wheel nuts 7 Remove the wheel 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 88 MAINTENANCE Tires Wheel Installation A WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Always ensure that all nuts are torqued to specification Do not service axle nuts that have a cotter pin installed See your Polaris dealer 5 6 Place the transmission in gear Lock the parking brake Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation Install the wheel nuts and fin ger tighten them Make sure the tapered side of the rear wheel nut fits into the taper on the wheel Lower the vehicle to the ground Tapered Nut Torque the wheel nuts to specification Axle and Wheel Nut Torque Specifications Check the following nuts for tightness occasionally and when they ve been loosened for service Nut Type Torque Front Spindle Nut s 100 in Ibs 11 Nm Front Wheel Nuts 27 ft Ibs 37 Nm Center and Rear Axle Nut s 80 ft Ibs 108 Nm Center and Rear Wheel Nuts 50 ft Ibs 68 Nm 89 MAINTENANCE Mir Filter Alwavs inspect and replace the air filter at the intervals
16. The following areas need special attention engine oil transmission oil front and rear gearcases and all grease fittings CAUTION Major engine damage can result if the vehicle is not thoroughly inspected after operation in water Perform the services outlined in the maintenance chart If your vehicle becomes immersed or is operated in water that exceeds the footrest level take it to your dealer for service before starting the engine NOTE Avoid operating the vehicle through deep or fast flowing water If you cannot avoid water that exceeds the recommended maximum depth go slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes If your vehicle becomes immersed and it s impossible to take it to a dealer before starting it follow the steps described on page 98 Have the vehicle serviced by your dealer at the first opportunity 65 OPERATION Driving Safelv Driving Over Obstacles Be alert Look ahead and learn to read the terrain you re traveling on Be constantly alert for hazards such as logs rocks and low hanging branches A WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle Not all obstacles are immediately visible Travel with caution in unfamiliar terrain 66 OPERATION Driving Safelv Driving in Rever
17. and lower fuel consumption Although Polaris Premium 4 is the only oil recommended for use in this engine use of any API certified SH oil is allowable as long as it s OW 40 Oil may need to be changed more frequently if Polaris Premium 4 is not used Follow the manufacturer s recommendations for ambient tem perature operation CAUTION Mixing brands or using a non recommended oil may cause serious engine damage We recommend the use of Polaris Premium 4 synthetic oil or another OW 40 API certified SH oil Never substitute or mix oil brands 76 Engine Oil Oil Level The oil dipstick is on the left side of the ATV 1 Position the vehicle on a level surface 2 Start the engine Allow it to idle for 20 30 seconds Stop the engine 3 Remove the dipstick Wipe it dry with a clean cloth 4 Reinstall the dipstick securely NOTE The dipstick must be fully installed to ensure an accu rate measurement 5 Remove the dipstick and check the oil level 6 Add oil as needed Maintain the oil level in the safe range Do not overfill NOTE Ifthe oil level rises above the full safe mark water and or fuel may be collect ing in the tank Change the oil MAINTENANCE Safe Range mW C Add Oil Safe Full 77 MAINTENANCE Oil and Filter Change A CAUTION Hot oil can cause serious burns to skin Do not allow hot oil to contact skin If the ATV is left without oil in the syste
18. attach tie straps to the front A arm bolt pockets 6 Remove the key to prevent loss during transporting 114 ADJUSTMENTS Camber and Caster The camber and caster are non adjustable Handlebars The handlebars can be adjusted for rider preference A WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars resulting in loss of control and possible serious personal injury or fea Follow the adjustment procedures exactly or see your Polaris dealer or service 1 Remove the upper headlight pod 2 Loosen the four handlebar bolts 3 Adjust the handlebar to the desired height NOTE Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right 4 Torque the front two bolts to 10 12 ft Ibs 14 17 Nm then 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 115 ADJUSTMENTS Throttle Cable Freeplav Adjust throttle cable freeplav at the handlebar 1 Locate the throttle cable adjuster at the handlebar 2 Squeeze the end of the rub ber boot and slide it far enough to expose the end of the inline cable adjuster 3 Loosen the adjuster lock nut Rotate the boot to turn the adjuster until 1 16 to 1 8 1 5 3 mm of
19. before riding The lever should feel firm when squeezed Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before operating See your dealer for proper diagnosis and repairs A WARNING Operating the ATV with a spongy brake lever can result in loss of braking which could cause an accident Never operate the ATV with a spongy feeling brake lever Auxiliary Brake Lever The auxiliary brake lever is located on the right handlebar It controls braking action for the middle axle rear brake only ree Use the auxiliary brakes for addi LIU tional braking or for backup if the kug service brake system fails 37 FEATURES AND CONTROLS Brake Svstems Master Cvlinders Brake Fluid The master cvlinders are located on the left and right handlebars Check fluid levels before each use of the ATV The fluid level can be seen Master Cylinder through an indicator window on the top of the master cylin der This eye will appear dark when the fluid level is full When fluid is low the eye will FREESE be clear Sigs NOTE When checking the fluid level the ATV must be on level ground with the handlebars straight If the fluid level is low add DOT 4 brake fluid only Do not overfill See page 126 for the part numbers of Polaris products Indicator Window Under normal operation the diaphragm extends
20. belt Improper break in Always break in a new belt and or clutch See page 51 120 Engine Doesn t Turn Over Possible Cause Low batterv voltage TROUBLESHOOTING 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 Turn fuel valve to reserve refuel Clogged fuel valve or filter Inspect and clean or replace Water is present in fuel Drain the fuel svstem and refuel Old or non recommended fuel Replace with fresh recommended fuel Fuel valve is turned off Turn the fuel valve on Fouled or defective spark plug s 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 Overuse of choke Low battery voltage Inspect clean and or replace spark plugs Recharge the battery to 12 8 VDC Mechanical failure See your dealer Engine Backfires Possible Cause Weak spark from spark plug Solution Inspect clean and or replace spark plug s 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
21. engine for this vehi cle as an LSI engine which produces 25 and greater horsepower and the vehicle has a six 6 or four 4 wheel drive and or a round steering wheel In California this LSI engine must be designed built and equipped to meet the state s stringent anti smog standards Polaris must warrant the emission control system on your LSI engine for the period of time described below provided there has been no abuse neglect or improper mainte nance of your LSI engine Your emission control system includes parts such as the carburetor and the ignition sys tem Also included may be hoses connectors and other emission related assemblies Where a warrantable condition exists POLARIS will repair your LSI engine at no cost to you including diagnosis parts and labor Manufacturer s Warranty Coverage The 2006 and later LSI engines are warranted for two 2 years If any emission related part on your LSI engine is defective the part will be repaired or replaced by POLARIS Owner s Warranty Responsibilities e As the LSI engine owner you are responsible for the performance of the required maintenance listed in your Owner s Safety and Maintenance Manual herein Owner s Manual POLARIS recommends that you retain all receipts covering maintenance on your LSI engine but POLARIS cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance As the LSI engine owner you
22. into the reservoir as fluid level drops If the fluid level is low and the diaphragm is not extended a leak is likely and the diaphragm should be replaced To ensure proper diaphragm operation always fill the reservoir as needed whenever the cover is loosened or removed Do not overfill A WARNING An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill A WARNING Never store or use a partial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of accident or severe injury After opening a bottle of brake fluid always discard any unused portion 38 FEATURES AND CONTROLS Parking Brake A WARNING Operating the ATV while the parking brake is engaged could result in an accident and serious injurv or death Alwavs check to be sure the parking brake is disengaged before operating Locking the Parking Brake 1 Squeeze and release the brake lever two or three times then squeeze and hold gt OY 2 Push the parking brake lock B A e forward to engage the lock IU Hit 3 Release the brake lever oo 4 To release the parking brake lock squeez
23. load ona 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 Maximum Cargo Capacities Level Ground Total Cargo 875 Ibs 397 kg Front Rack Cargo 75 Ibs 34 kg Cargo Box 800 Ibs 363 kg Maximum Towing Capacities Towed Load level ground 1500 Ibs 681 kg Towed Load up to 15 incline 850 Ibs 386 kg Vertical Hitch Weight 150 Ibs 68 kg Towing Grade 15 55 OPERATION Hauling Cargo Dumping Cargo f Latch 1 Select a level site to dump Release the cargo Do not attempt Lever to dump or unload the vehicle while parked on an incline 2 Lock the parking brake Box Lift 3 Dismount the vehicle Handle 4 Check cargo distribution If cargo has shifted to the rear of the box exercise caution A WARNING If the weight distribution in the box is located toward the rear of the box when the release lever is pulled forward the box may dump on its own which could cause serious injury Never operate the dump lever without checking the position of the load This will prevent unexpected dumping of the cargo box Never carry passengers in the cargo box 5 Pull the cargo box release lever forward 6 Lift the front of the cargo box to dump the cargo 7 Lower the cargo box Make sure the latch is secure before operating 56 OPERATION Hauling
24. of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the ATV RiderCoursest offered by Polaris through the SVIA They should then regularly practice the skills learned in the course and the operating techniques described in the Owner s Manual For more information about the ATV RiderCourses contact ATV Enrollment Express at 800 887 2887 or visit www atvsafety org A WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV WHAT CAN HAPPEN Severe injury and or death could occur if a child under the minimum age WA recommendation operates an ATV Even though a child mav be within the lt 1 6 recommended age group for operating some ATVs he she may not have the skills abilities or judgment needed to operate an ATV safely and could be susceptible to accident or injury HOW TO AVOID THE HAZARD No one under the age of 16 should operate a Polaris ATV 19 SAFETV Operator Safetv A WARNING POTENTIAL HAZARD Carrving a passenger on an ATV WHAT CAN HAPPEN X Carrying a passenger greatly reduces the operator s ability to balance and z control the ATV which could cause an accident and injury to the operator and or passenger A passenger riding on a rack or in the cargo bed can fall from the vehicle which could result in serious injury HOW TO AVOID THE HAZARD Never carry a passenger A WARNING POTENTIAL
25. outlined in the Periodic Maintenance Chart beginning on page 70 1 Remove the seat 2 Release the air box cover clips Pre Filter and remove the air box cover Main Filter 3 Loosen the clamp and remove the filter 4 Remove the fabric type pre fil ter from the main filter Wash the pre filter in soapy water then rinse and let dry 5 Reinstall the pre filter over the main filter NOTE Install a new main filter if needed 6 Reinstall the filter into the air box and tighten the clamp Do not over tighten the clamp as filter damage could occur 7 Reinstall the air box cover and the seat CAUTION Operation of your vehicle without a pre filter can cause engine damage Always reinstall the pre filter after removing it for service Air Box Drain Periodically check the air box drain tube located on the bottom rear of the air box Empty the drain tube if necessary 90 MAINTENANCE Breather Filter Hose Alwavs inspect and replace the breather filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 70 1 Remove the hose clamps from the filter and pull the filter out of the hoses NOTE It s not necessary to remove the lower hose from the engine 2 Inspect the filter for debris Blow gently through the fil ter in the direction of the arrow to check for clogging Replace a damaged or Breather Filter clogged filter 3 Check the hoses for cracks deterio
26. pulling immediately 3 Allow the recoil rope to rewind into the recoil assembly then pull the rope abruptly and forcefully to start the engine 4 Repeat all steps until the engine starts 5 Make sure the handle is fully seated on the housing CAUTION Extending the recoil starter rope until it stops can cause damage to the recoil assembly Do not extend the starter rope so far that it stops If the starter rope handle is not seated properly water may enter the recoil housing and damage components Make sure the handle is fully seated on the recoil housing especially when traveling in wet areas 42 FEATURES AND CONTROLS All Wheel Drive AWD System The All Wheel Drive system is controlled by the AWD switch When the switch is off the vehi cle is in rear wheel drive at all A mm times When the switch is on the vehicle is in AWD and the front Dm AWD wheels will automatically engage Switch any time the rear wheels lose trac tion When the rear wheels regain traction the front wheels will automatically disengage NOTE The override switch allows activation of AWD in reverse if the AWD switch is on See page 34 There is no limit to the length of time the vehicle may remain in AWD The AWD switch may be turned on or off while the vehicle is moving If the switch is turned off when the front hubs are driving they will not release until the rear wheels regain traction CAUTION Switching t
27. should however be aware that POLARIS may deny you warranty coverage if your LSI engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for presenting your LSI engine to a dealer authorized by POLARIS as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days If you have any questions regarding your warranty rights and responsibilities you should contact the Polaris Warranty Department at 1 763 417 8650 132 WARRANTV California Emission Control Warrantv Statement Limited Warrantv California Only POLARIS warrants to the owner of 2006 and later LSI engines that the LSI engine 1 has been designed built and equipped at the time of manufacture so as to conform with the applicable regulations of the California Air Resources Board and 2 is free from defects in materials and workmanship which may cause it to fail to conform with those regulations as applicable according to the terms and conditions stated below Warranty Period This warranty period begins on the date which the LSI engine is delivered to the origi nal retail purchaser and ends two years after that date During this two year period POLARIS warrants to the original retail purchaser and each subsequent purchaser that the LSI engine is free from defect in material and workmanship that can cause the fail ure of a warranted emission related par
28. software version installed in your ATV This information is displayed briefly Use the mode reverse override button to toggle through the diagnostic screens Screen 1 Battery voltage Screen 2 Tachometer Screen 3 AWD diagnostic This gauge indicates whether or not current is flowing through the AWD coil only on models with switchable AWD Screen 4 Gear circuit diagnostic This screen displays the resistance value in ohms being read at the gear switch input of the gauge 48 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Screen 5 Programmable service interval The purpose of the programmable service interval is to provide the con sumer and dealer with a convenient reminder for routine maintenance When vour vehicle leaves the factorv this feature is set at 50 hours Vou must enable the programmable service interval before it can be used Once the service interval mode is set with the hours when service is due the hours of actual engine operation are subtracted from the set hours until 0 is reached When the counter reaches 0 the wrench icon will flash quickly for 5 seconds each time the vehicle is started as a reminder that the periodic maintenance is due To set the hours press and hold the mode override button until the wrench icon flashes When it begins to flash release the button The set ting will increase by one hour each time the button is pressed Pressing and holdi
29. stops NOTE The variable choke is fully on when the knob is pulled com pletely out The choke is off when the knob is pushed completely in The choke can be adjusted gradually depending on how much choke is needed for starting Be sure the choke is off dur ing operation as excess fuel washing into the engine oil will increase wear on engine components Tension NOTE If the knob doesn t stay Adjusting Nut where positioned increase the tension by rotating the tension adjusting nut clock wise 7 Move the engine stop switch to RUN NOTE Do not press the throttle while starting the engine 53 OPERATION Starting the Engine 8 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 9 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 NOTE Ifa warm engine has cooled to a point where it does not readily start intermittent use of the choke button pulled half way out may be nec essary If the engine is over choked when warm depress the throttle lever fully while cranking to aid in starting Release the throttle lever immediately after the engine starts If the engine does not start and all conditions are favorable change the spark plug and
30. the possibilitv of an accident or equipment damage HOW TO AVOID THE HAZARD Alwavs inspect vour ATV before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the owner s manual 23 SAFETV Operator Safetv A WARNING POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation WHAT CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV If the operator s foot is not firmly planted on the footrest it could contact the rear wheels and lead to accident or injury HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation A WARNING POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn i HOW TO AVOID THE HAZARD F Travel slowly and use extra caution when Bel SAT operating on unfamiliar terrain Alwavs be ENA Y alert to changing terrain conditions 24 SAFETV Operator Safetv A WARNING POTENTIAL HAZARD Failure to use extra caution when operating on excessivelv rough slipperv or loose terrain WHAT CAN HAPPEN Operating o
31. towing can cause changes in vehicle handling which could lead to loss of control or an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow a greater distance for braking Always follow the instructions in the owner s manual for carrying cargo or pulling a trailer A WARNING POTENTIAL HAZARD Operating on frozen bodies of water WHAT CAN HAPPEN Severe injury or death can result if the ATV and or the operator fall through the ice HOW TO AVOID THE HAZARD Never operate the ATV ona frozen body of water 32 SAFETV Operator Safetv A WARNING Operating a damaged ATV can result in an accident with serious injurv or death 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 A WARNING Safe operation of this rider active vehicle requires good judgement and phvsical skills Persons with cognitive or phvsical disabilities who operate this vehicle have an increased risk of overturn and loss of control which could result in severe injurv or death A WARNING Exhaust svstem components are verv hot during and after use of the vehicle Hot components can cause serious burns and fire Do not touch hot ex
32. try again 10 If the engine slows or stops position the choke knob half way in to allow proper engine warm up Vary the engine RPM slightly with the throttle to aid in warm up When the engine idles smoothly push the choke completely in CAUTION Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle 54 OPERATION Hauling Cargo Your ATV has been designed to carry or tow a certain amount of load Always read and understand the load distribution warning labels on the vehicle and never exceed the weight capacities outlined in the specifi cations section of the owner s manual and on the safety decals A WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability e Never exceed the stated load capacity for this vehicle Do not obstruct the headlight when loading the front rack e Cargo should be properly distributed and carried as low and forward in the cargo box as possible e Reduce speed and allow a greater distance for braking e Use extreme caution when applying brakes with a loaded e vehicle Avoid terrain or situations that may require backing downhill e Always attach the tow load to the hitch point e Do not tow any trailer on a grade steeper than 15 e Vehicle should never exceed 10 mph 16 kph while towing a
33. who sold you the LSI engine or a dealer authorized by POLARIS In the event that any emis sion related part is found to be defective during the warranty period you must notify the Polaris Warranty Department at 1 763 417 8650 and you will be advised of the appro priate dealer where the warranty repair is to be performed 135 WARRANTV U S A EPA Emissions Limited Warrantv This All Terrain Vehicle ATV or Off Road Utility Vehicle ORUV emissions limited warranty is in addition to the Polaris standard limited warranty for this vehicle Polaris warrants that this vehicle is 1 designed built and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and 2 free from defects in materials and workmanship that may keep it from meeting these requirements The emissions warranty period for this vehicle begins on the date the vehicle is deliv ered to the original retail purchaser and ends 30 months 2 5 years after that date or after 5000 km 3100 miles whichever comes first This emission related warranty covers components whose failure would increase an engine s emissions including electronic controls fuel injection exhaust gas recircula tion aftertreatment or any other system utilized in this vehicle to control emissions Replacing or repairing other components not covered by this emissions warranty or the standard warranty is the responsibility of the owner including the parts labor and other
34. your dealer for service as soon as possible whether you succeed in starting it or not If water has been ingested into the PVT follow the procedure on page 102 for drying out the PVT MAINTENANCE Spark Arrestor A WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injurv or death The exhaust svstem can get extremelv hot Do not perform service on the spark arrestor while the svstem is hot Allow components to cool sufficientiv before proceeding Remove anv combustible materials from the area Wear eve protection and leather work gloves Do not stand behind or in front of the vehicle while purging Never run the engine in an enclosed area Exhaust contains je carbon monoxide gas Never go under the vehicle while it s inclined Use the following procedure to periodicallv purge accumulated carbon from the exhaust pipe muffler 1 Remove the arrestor clean out plug from the bottom of the muffler 2 Place the transmission in eae neutral 0 3 Start the engine d T 4 Quickly squeeze and release Clean Out Plug 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 protective 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 f
35. 44 FEATURES AND CONTROLS Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel The instrument cluster measures dis tance in miles or kilometers as well as hours of operation It also includes a reverse speed limiter function that limits the ATV s speed to approximately 7 9 mph Refer to page 34 for additional information Speedometer Needle Speedometer Rider j Bay ih Information Center NOTE In addition to showing vehicle speed the speedometer needle flashes when a warning condition exists CAUTION High water pressure may damage ATV components Wash the ATV by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage the speedometer lens and other plastic surfaces Do not use alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens Immediately clean off any gasoline that splashes on the instrument cluster 45 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 NOTE Ifthe instrument cluster fails to illuminate a battery over voltage may 46 have occurred and the instrument cluster may have shut off to protect the electronic speedometer If this occurs take the ATV to your Polaris dealer for
36. 6 years of age 12 SAFETV Operator Safetv Safetv Training ATV safety training is a top priority for Polaris When you purchased your new ATV your dealer instructed you on the authorized ATV RiderCourse available to you and your eligible family members This training is included in the purchase price of your ATV Polaris strongly encourages you and your eligible family members who will be riding the ATV to take the ATV RiderCourse You were also provided with printed materials that explain safe operating procedures You should review this information on a regular basis If you purchased a used Polaris ATV you can take the ATV RiderCourse by calling ATV Enrollment Express at 800 887 2887 or by visiting www atvsafety org Purchasers of a used Polaris ATV will be charged for this training A Polaris ATV is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this 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 13 SAFETV Operator Safetv 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 t
37. Adjustment 119 Engine Oil 76 77 Equipment Modifications 18 Exhaust Emission Control System 69 Eye Protection 11 F Fuel Safetv 0 00000000 50 Fuel Tank Cap 0 40 G Gear Selector 0 41 Gearcase Oil Front 82 Gloves mma pnoy dagtetena a 11 H Handlebar Adjustment 115 Hauling Cargo 55 57 Headlight Housing Replacement 94 Headlight Lamp Replacement 92 Headlight Switch 35 Helmet re ae i Sas acre n wa 10 High Beam Adjustment 93 High Range 102 l J K Idle RPM Adjustment 119 Immersion LL niuunae 98 Instrument Cluster 45 49 Jetting Chart 0 125 Key Switch restu snose mannas ais 35 KATUN eea nia oe nan iea Blat a 64 L Lights Headlight Housing Replacement 94 Headlight Lamp 92 High Beam Adjustment 93 Low Beam Adjustment 94 Lower Headlamp Replacement 95 Taillight Brakelight 95 Load Distribution 57 Low Beam Adjustment 94 L Low Ranges i se e esa ee 102 Lower Headlamp Replacement 95 Lubrication Recommendations 74 75 M Maintenance Chart 70 73 Master Cylinder 38 Mode Switch 0000 0 34 Modifications 18 N Noise Emission Control Svstem 69 O Oil Engine 76 77 Front Gearcase 82 Tr
38. Alwavs follow proper procedures for climbing hills Check the terrain carefully before ascending a hill Never climb hills with excessively slippery or loose surfaces Shift your weight uphill Never open the throttle suddenly or make sudden gear changes Never go over the top of a hill at high speed Always follow proper procedures for going downhill and for braking on hills Check the terrain carefully before you start down a hill Shift your weight uphill Never go down a hill at high speed Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side Drive straight downhill Always follow proper procedures for crossing the side of a hill Avoid hills with excessively slippery or loose surfaces Shift your weight uphill Never attempt to turn the ATV around on any hill until you ve mastered on level ground the turning technique outlined in this manual Avoid crossing the side of a steep hill when possible Always use proper procedures if you stall or roll backwards while climbing a hill To avoid stalling maintain a steady speed when climbing a hill If you stall or roll backwards follow the special pro cedure for braking described in this manual Always dismount on the uphill side or to either side if the ATV is pointed straight uphill Turn the ATV around and remount following the procedure described in this manual SAFETV Operator Safetv Alwavs check for obstacles before operating in a new area
39. ING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm 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 acces sories available through our online store at www purepolaris com Have your accessories and clothing delivered right to you
40. IS 1965 LBS 893 kg Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your risk of losing control Loads should be centered carried as low as possible in bed and firmly secured to the rack For stability on rough or hilly terrain reduce speed and cargo Do not block headlight Be careful if load extends over the side of the rack or box Read Owner s Manual for more detailed loading information Front Rack Box Warning WARNING DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death Tow only from tow hooks or hitch Max combined Front Rack and container Load 75 Ibs 34 kg Reverse Override Warning WARNING Pushing reverse override button may cause sudden increases in power and traction if too much throttle is applied Loss of control or forward flipover may result especially in AWD See Owner s Manual SAFETV Safetv Decals and Locations Age 16 Warning Container No Passenger TA Warning Clutch Cover Warning Age 16 Warning WARNING Operating this ATV if vou are under the age of 16 increases vour chance of severe injurv or death NEVER operate this ATV if vou are under age 16 Container No Passenger Warning WARNING Remove flammable containers from box before refueling WARNING e Passengers can be thrown off This can cause serious injury or death e Never carry passen
41. Maintenance Chart beginning on page 70 Items not listed in the chart should be lubricated at the general lubrication interval NOTE 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 O ring chain lube or SAE 80 90 Item Lube Method Engine Oil Polaris Premium 4 Synthetic See page 77 OW40 Brake Fluid DOT 4 Only See page 38 Drive Chains Lubricate as often as required before each ride in wet condi tions Gear Selector Oil Polaris Premium 4 Svnthetic OW40 Maintain oil level at the center of the shift rail Do not overfill Transmission Oil Polaris Premium Svnthetic Gearcase Lube See page 81 Front Prop Shaft Yoke Polaris Premium U Joint Lube Grease fittings 3 pumps maxi mum every 500 miles before long periods of storage or after pres sure washing or submerging AWD Hubs Premium Demand Drive Hub Fluid Remove set screw in hubs Rotate wheels to 4 00 position see illus tration on next page If lubricant is not visible add more Reinstall set screw Ball Joint Rear Axle Bearing Swing Arm Bushings Polaris Premium all Season Grease or grease conform ing to NLGI No 2 Locate zerk on back side of struts and grease with grease gun Locate fi
42. Miscellaneous Items Used in Above Systems 1 Electronic controls if applicable ii Hoses belts connectors and assemblies iii Filter lock assy gaseous fuel if applicable If an authorized dealer determines that other LSI engine components have been dam aged due to the failure of a warranted emission related part during the warranty period POLARIS will repair and or replace the necessary components 133 WARRANTV California Emission Control Warrantv Statement What is Not Covered Under This Warrantv This warrantv does not cover anv emission related part which malfunctions fails or is damaged due to alterations and or modifications such as changing adding or removing parts When the LSI engine is being serviced under warranty POLARIS and any of its autho rized dealers shall not be liable for any loss of use of the LSI engine for any damage to goods or loss of time or inconvenience This limited warranty also does not apply to any emission related part which malfunctions fails or is damaged due to failure to follow the maintenance and operating instructions specified in the 2006 and later Owner s Man ual including a Improper or inadequate maintenance of any warranted emission related part b Improper installation adjustment or repair of the LSI engine or any warranted emission related part unless performed by an authorized dealer c Failure to use recommended fuel as specified in the 2006 and later Owner s Manua
43. Read this manual carefully It contains important safety information This is an adult vehicle only tion is Sore for those under 16 years of age gt Improper vehicle use can result in SEVERE INJURY or DEATH NEVER e Operate on public roads A collision can occur with another vehicle e Carry passengers Passengers affect balance and steering and increase risk of losing control e USE ALCOHOL or DRUGS before or while operating this vehicle e Operate at speeds too fast for your skills or the conditions e Operate this vehicle on HILLS steeper than 15 degrees To prevent flipover on hilly terrain use throttle and brakes gradually ALWAYS e Use an approved HELMET AND PROTECTIVE GEAR e Avoid paved surfaces Pavement may seriously affect handling and control e Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills and rough terrain and in turns e Use OVERRIDE for reverse speed limiter with caution To prevent loss of control never activate override button with open throttle REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent flipover avoid sharp turns PARKING BRAKE may relax when used for more than 5 minutes When parking on grades leave shift in forward LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS IF OWNER S MANUALIS MISSING CONTACT A POLARIS DEALER FOR A REPLACEMENT Part No 9920775 PRINTED IN THE USA A WARN
44. Use Operating at speeds less than 7 MPH 11 km h Low Towing heavv loads Low Operating in rough terrain swamps mountains etc Low Operating at speeds greater than 7 MPH 11 km h High PVT Drving There mav be some instances when water is accidentiv ingested into the PVT system Use the following instructions to dry it out before operat ing 1 Remove the drain plug Allow the water to drain completely Rein stall the drain plug 2 Start the engine Place the transmission in neutral Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches NOTE Do not hold the throttle wide open for more than 10 seconds 3 Allow the engine RPM to settle to idle speed then shift the trans mission to the lowest available range 4 Test for belt slippage If the belt slips repeat the process 5 Take the vehicle to your dealer for service as soon as possible 102 MAINTENANCE Batterv 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 Conventional 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 d
45. aily 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 tail Daily Check operation apply lamp dielectric grease if replacing gt Air filter Weekly Inspect replace as needed E main element Recoil housing Weekly Drain water as needed check often if operating in wet conditions 71 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km gt Brake pad wear 10H Monthly 60 100 Inspect periodically gt Engine oil change 20H 1M 125 200 Perform a break in oil change break in at one month Battery 20H Monthly 125 200 Check terminals clean test gt Front gearcase oil 25H Monthly 155 250 Inspect level change yearly if equipped gt Middle gearcase 25H Monthly 155 250 Inspect level change yearly oil if equipped gt Rear gearcase oil 25H Monthly 155 250 Inspect level change yearly if equipped gt Transmission oil 25H Monthly 155 250 Inspect level change yearly gt Engine breather 25 H Monthly 155 250 jInspect clean if needed E jfilter if equipped gt General 50H 3M 310 500 Lubricate all fittings pivots lubrication cables etc Shift
46. and air filter 2 Clean the air box 3 Drain the sediment tube Recoil Housing Drain the recoil housing See page 97 112 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 70 Engine Anti Freeze Test engine coolant strength and change if necessarv Replace coolant EVETV tWO Vears Batterv Storage See pages 106 107 for storage and charging procedures Storage Area Covers Set the tire pressure and safely support the ATV with the tires slightly off the ground Be sure the storage area is well ventilated Cover the Vehicle with a genuine Polaris cover NOTE Do not use plastic or coated materials They do not allow enough ven tilation to prevent condensation and may promote corrosion and oxi dation Accessories Auxiliary 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 Please see your Polaris dealer 113 MAINTENANCE Transporting the Vehicle Follow these procedures when transporting the vehicle 1 Stop the engine 2 Place the transmission in gear 3 Lock the parking brake Secure the fuel cap oil cap and seat 5 Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope Do not
47. ansmission 81 Oil and Filter Change 78 80 Oil Level Engine 77 Oil Pump Priming 80 Operator Safetv 12 33 Override Switch 0 34 P Parking Brake 39 Parking on an Incline 68 Periodic Maintenance Chart 70 73 Polaris Product List 126 Polishing the Vehicle 110 Premium 4 Synthetic Lubricant 76 Pre Ride Checklist 52 PVT Break In 51 PVT Drying 2 102 PVT System 100 102 R Rear Brake 0 85 Recoil Housing 97 Recoil Starter 0 0000 42 Reverse Operation 67 Reverse Override Switch 34 Rider Information Center 46 49 Riding Gear 10 11 S Safety Decals Age 16 Warning 8 All Wheel Drive Switch 9 Clutch Cover Warning 8 Container No Passenger Warning 8 Front Rack Box Warning 7 General Warning 6 Hitch Capacitv Label 9 Reverse Override Warning 7 Tire Pressure Load Warning 7 S Safety Training 13 SEVEL USE p i 70 Side Panel Removal 87 Sidehilling L nnaa unean 62 Signal Words oonu unuunu 14 Spark Arrestor 99 Spark Plug Recommendations 96 Spark Plugs 000 00 96 97 Starting the Engine 53 54 Steering Assem
48. bly 87 Storage Tips 111 113 Suspension Springs Optional 118 Switches AWD Switch 43 Engine Stop Switch 35 Headlight Switch 35 Main Key Switch 35 Mode Reverse Override Switch 34 T Taillight 000000 95 Throttle Body Adjustment 116 Throttle Cable Freeplay Adjustment 116 Throttle Lever 0 36 Tires Front Wheel Hub Tightening 88 Tire Tread Depth 88 Wheel Installation 89 Wheel Nut Torque 89 Wheel Removal 88 Toe Alignment 86 Towing Capacities 55 Training 13 Transmission OQil 81 Transporting the Vehicle 114 Turning Around ona Hill 64 Turning the Vehicle 59 V Vehicle Identification Numbers 5 Vehicle Immersion 98 VIN wind tostea Bet eo bee ee Wok 5 Ww Warning Symbols 14 Washing the Vehicle 109 110 Wheel Hub Tightening 88 Wheel Installation 89 Wheel Nut Torque Specifications 89 Wheel Removal 88 141
49. ce with fresh recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction Electronic throttle control malfunction See your dealer See your dealer Other mechanical failure See your dealer Overheated engine Engine Overheating Possible Cause Debris lodged in screen Clean radiator screen and core clean engine exterior see vour dealer Solution Remove and clean the screen Pull on the top portion of the screen then remove the lower portion Plugged Radiator Use a garden hose to flush any debris from the radiator fins NOTE High pres sure washers can deform the radiator fins and reduce cooling efficiency 123 SPECIFICATIONS Sportsman 500 6X6 Gross Vehicle Weight 1965 Ibs 891 kg machine driver cargo Fuel Capacitv 4 25 gal 16 1 Engine Oil Capacity 2 qts 1 9 1 Coolant Capacity 2 25 qts 2 1 Transmission Oil Capacity 32 oz 948 ml Front Gearcase Oil Capacity 4 oz 120 ml Front Rack Storage Box Capacity 75 Ibs 34 kg Cargo Box Capacity 800 Ibs 363 kg Hitch Tongue Capacity 150 Ibs 68 kg Hitch Towing Rating 1500 Ibs 680 4 kg Unbraked Trailer Towing Capacity 1900 Ibs 863 kg Overall Length 105 in 267 cm Overall Width 46 in 117 cm Overall Height 48 in 122 cm Wheelbase 77 in 196 cm
50. costs associated with recommended maintenance The exclusive remedy for breach of this limited warranty shall be at the exclusive option of Polaris repair or replacement of any defective materials components or 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 CONSEQUENTIAL 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 any engine that has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire exp
51. d checking chain tension in several places around the chain 9 Reinstall the chain guard NOTE Reposition the chain guide to allow 1 8 3 mm clearance between the sprocket and guide 117 ADJUSTMENTS Rear Axle Drive Chain To adjust the rear axle drive chain loosen the rearmost eccentric locking bolts and rotate using the same method as outlined for the front chain adjustment Total slack for the rear chain should be adjusted to 3 8 1 2 9 13 mm at the tightest point in the chain 3 8 1 2 9 13 mm Optional Suspension Springs Although the suspension has the capability of providing the best ride possible the following accessory springs are available to better suit individual riding preferences NOTE Optional springs may be a different color than standard springs Springs may be painted to a desired color using Polaris touch up paint available through Polaris dealers SOFT lt gt FIRM Front Strut Spring 7041375 067 7041450 067 None OPTION STANDARD 64 113 Ib in 101 Ib in 118 ADJUSTMENTS Carburetor Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6 000 feet 1800 m and temperatures of 40 degrees F 4 degrees C or higher Above 6000 feet 1800 m the engine air fuel mixture becomes overly rich and the engine loses approximately 3 of its power for each 1000 foot 304 8 m increase in elevation Although this power ca
52. e and release the brake lever It will return to its unlocked position Important Safeguards The parking brake may relax if left on for a long period of time 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 posi tion Never depend on the parking brake alone if the ATV is parked on a hill Always block the wheels to prevent rolling 39 FEATURES AND CONTROLS Fuel Tank Cap Remove the fuel tank cap to add fuel Fuel Tank to the fuel tank Use either leaded or Fuel Valve Cap unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Do not use E 85 fuel Fuel Valve The fuel valve is located on the left side panel It has three positions OFF For vehicle storage and when transporting ON For normal operation RES For reserve supply if main sup ply is exhausted There s about a 7 to 10 mile 11 2 to OFF 16 km range on the reserve supply Always refill the gas tank as soon as possible after using the main supply ON Always return the valve to the ON position after refueling 40 FEATURES AND CONTROLS Transmission Gear Selector The transmission gear selector is Gear located on the right side of the Selector Vehicle H High Gear L Low Gear aa N Neutral R Reverse To change gears stop the vehi cle and with the engine idling move the lever to th
53. e desired gear Do not attempt to shift gears with engine speed above idle or while the vehicle is mov ing Always place the transmission in gear and lock the parking N brake whenever the vehicle is left unattended Maintaining shift linkage adjustment is important to assure proper transmission R function See your dealer if you experience any shifting problems CAUTION Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage To change gears stop the vehicle and with the engine idling move the lever to the desired gear 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 41 FEATURES AND CONTROLS Recoil Starter If the batterv is too weak to start the engine use the recoil starter The recoil starter is located on the right side of the vehicle Follow the starting procedures on page 53 crank ing the engine with the recoil starter instead of the main key switch 1 Grasp the recoil starter rope handle tightly 2 Pull slowly so you can feel the engine strokes Handle Recoil Starter NOTE Every other stroke will be a compression stroke and will make the rope harder to pull When a compression stroke is found continue pulling the rope just until the engine rolls past the stroke then stop
54. e downhill side Turn the fuel valve off go sre eee 68 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 205 158 and local noise level requirements Operation on Public Lands in the U S A Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100 1C Fed eral law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public lands in the U S A is regulated by 43 CFR 8343 Violations are subject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov 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 The emissions from the exhaust of this vehicle are controlled by engine design Emissions Label including factory set fuel delivery and ignition The engine and related compo nents must be maintained at Polaris speci fications to achieve optimal performance Engine idle speed is the only adjustment Polaris recommends that the operator per form Any other adjustments should be perfor
55. en the switch is off NOTE The taillight is on whenever the main key switch is on Turn the main key switch off to prevent battery drain Main Key Switch Turn the main key switch off to stop the engine To start the engine slide the stop switch to the center RUN position and turn the main key switch clockwise past the ON position Release the key when the engine starts Headlight Switch Use the headlight switch to turn the lights on and off and to change the lights from high beam to low beam NOTE The lights won t work unless the key is in the ON position A WARNING Operating the ATV on streets or roads especially in darkness could result in an accident and serious injury or death Your ATV is not equipped with highway approved lights It s designed for and must be used for off road use only Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness 35 FEATURES AND CONTROLS Throttle Lever A WARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death Never start or operate an ATV with a sticking or improperly operating throttle Always contact your dealer for service if throttle problems arise Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation Always check the lever for free
56. 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 By switching to low range while operating at low ground speeds the air temperature in the clutch cover is reduced by almost 160 degrees Reducing the temperature inside the clutch cover extends the life of the PVT components belt cover etc 101 MAINTENANCE PVT Svstem When To Use Low Range and High Range Condition Range to
57. ent 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 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 Climbing over large objects from a stopped position 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 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 102 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
58. fastener tightness BS Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels a Coolant level if applicable Ensure proper level 83 Coolant hoses if applicable Inspect for leaks Throttle Ensure proper operation TAG Indicator lights switches Ensure operation 34 Engine stop switch Ensure proper operation 35 Air filter pre filter Inspect clean 90 Air box sediment tube Drain deposits whenever visible Headlamp Check operation apply Polaris dielec 35 tric grease when lamp is replaced 92 Brake light tail lamp Check operation apply Polaris dielec 95 tric grease when lamp is replaced Dump box latch Check condition and operation of the 5 mechanism Riding gear Wear approved helmet goggles and 10 52 OPERATION Starting the Engine A WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injurv or death Never run an engine in an enclosed area 1 Position the vehicle on a level surface 2 Place the transmission in neutral 3 Lock the parking brake NOTE The starter interlock will prevent the engine from starting if the trans mission is in gear and the brake is not engaged 4 Turn the fuel valve on 5 Siton the vehicle NOTE Donotuse the choke if starting a warm engine Excessive use of the choke can cause the spark plug to become wet fouled 6 Ifthe engine is cold pull the choke knob out until it
59. freeplay is achieved at the thumb lever NOTE While adjusting freeplay be sure to flip the throttle lever back and forth 5 Tighten the lock nut 6 Squeeze the end of the rub ber boot and slide it over the cable adjuster to its original position 116 NA Boot Lock Nut Adjuster ADJUSTMENTS Front Drive Chain CAUTION Operating the vehicle with the drive chain slack out of specification could cause serious damage to the transmission and drive components Never operate the vehicle with the drive chain slack out of specification Check the amount of chain slack bv moving the vehicle slightly forward to gain slack at the top side of the front chain Then pull up and down on the chain At this point the chain should have 3 8 1 2 9 13 mm deflection If the chain needs adjust CE ment use the following procedure i a wai 1 Remove the chain guard and ed se loosen the chain guide opening positon 2 Loosen the two eccentric lock ing bolts 3 Loosen the caliper mount bolts Pin Punch 4 Insert a pin punch through the Lt sprocket hub and into the eccen poi Calle tric axle housing 5 Roll the vehicle forward or rear ward to adjust chain slack to the proper dimension Locking Bolts 6 Tighten the caliper mount bolts to 10 12 ft Ibs 13 5 16 3 Nm Tighten the eccentric locking bolts to 60 ft Ibs 80 Nm Confirm correct tension by rolling the vehicle forwar
60. gers Maximum Box Load 800 Ibs 363 kg Clutch Cover Warning WARNING NO STEP e Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed e 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 SAFETV Safetv Decals and Locations All Wheel Drive Switch Do not push switch to engage AWD if the rear wheels are spinning This mav cause severe drive shaft and clutch damage See vour Owner s Manual Hitch Capacitv Label TRAILER MAX WEIGHT 1500 LBS 682 KG ON LEVEL GROUND 850 LBS 386 KG UP TO 157 GRADE HITCH MAX VERTICAL WEIGHT 150 LBS 68 KG 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 Helmet Gloves Long Pants d Helmet Wearing a helmet can prevent a severe head injury Whenever riding a Polaris vehicle always wear a helmet that meets or exceeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has 051039 granted approval The approval nu
61. haust svstem components Alwavs keep combustible materials awav from the exhaust svstem Use caution when traveling through tall grass especiallv drv grass A WARNING Leaving the kevs in the ignition can lead to unauthorized use of the vehicle resulting in serious injurv or death Alwavs remove the ignition kev when the vehicle is not in use 33 FEATURES AND CONTROLS Switches Headlight Switch AWD Switch Main Kev Switch Mode Reverse Override Engine Switch Stop Switch A WARNING Activating the override switch while the throttle is open can cause loss of control resulting in severe injurv or death Do not activate the override switch while the throttle is open Mode Reverse Override Switch This vehicle is equipped with a reverse speed limiter svstem To gain additional power while backing depress the override switch NOTE The override switch also allows activation of All Wheel Drive 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 45 All Wheel Drive AWD Switch See page 43 for AWD information 34 FEATURES AND CONTROLS Switches Engine Stop Switch Move the stop switch to the center OFF position to stop the engine quickly The stop switch provides the operator with a quick means of engine shutdown in case of stuck throttle or other emergencv The engine will not OFF ON OFF start or run wh
62. he manual A The safety alert symbol on your vehicle or in this manual alerts you to the potential for injury A WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death A CAUTION The safety alert caution indicates a potential hazard that may result in minor injury or damage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle NOTE A note will alert you to important information or instructions 14 SAFETV Operator Safetv A WARNING Serious injurv or death can result if vou do not follow these instructions and procedures which are outlined in further detail within vour owner s manual Read this manual and all labels carefully and follow the operating procedures described Never operate an ATV without proper instruction Take a training course Purchasers of a new Polaris ATV and their eligible family members are entitled to take the ATV RiderCourse Contact ATV Enrollment Express at 800 887 2887 or visit www atvsafety org for information on enrollment in the ATV Rider Courses Never allow anyone under 16 years of age to operate this ATV Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course Always avoid operating an ATV on paved surfaces including side walks driveways parking lots and street
63. he safety of others and the protection of our environment Read and understand vour owner s manual which includes valuable informa tion about all aspects of vour vehicle including safe operating proce dures 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 Decals and Locations Warning decals have been placed on the ATV for vour protection Read and follow the instructions of the decals on the ATV carefully If any of the decals depicted in this manual differ from the decals on your ATV always read and follow the instructions of the decals on the ATV If any decal becomes illegible or comes off contact your Polaris dealer to purchase a replacement Replacement safety decals are provided by Polaris at no charge The part number is printed on the decal General Warning WARNING Improper vehicle use can result in SEVERE INJURY or DEATH NEVER e Operate on public roads A collision can occur with another vehicle e Carry passengers Passengers affect bal ance and steering and increa
64. horized lubricants chemicals or fuels that are not compatible with the vehicle The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIP TION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law 128 WARRANTV ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITV AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTV 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 vehicle requires warranty service you must take it to a Polaris Servicing Dealer When requesting warranty service you must present your copy of the Warrant
65. in plug Allow the oil to drain completely 5 Clean and reinstall the drain plug Torque to 14 ft Ibs 19 Nm 6 Add the recommended oil See page 124 for capacities Maintain the oil level at the bottom of the fill hole threads 7 Reinstall the fill plug Torque to 14 ft Ibs 19 Nm 8 Check for leaks 9 Dispose of used oil properly 82 MAINTENANCE Cooling Svstem The engine coolant level is controlled or maintained bv the recoverv system The recovery system components are the recovery bottle 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 recovery 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 NOTE Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air Check the coolant level and maintain as recommended by adding coolant to the recovery 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 126 for the part numbers of Polaris products NOTE Always follow the manufacturer
66. ing 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 Adjusting 9 Reverse the steps to install the ni new housing and reassemble lamp parting line to the end of the adjustment knob stop the pod NOTE The distance from the head i k 4 5 l 10 Adjust the headlight aim by 94 is 5 1 8 13 cm turning the adjusting knob MAINTENANCE Lights Taillight Brakelight Lamp Replacement 1 Remove the taillight lens cover mounting screws Remove the lens cover and gasket and set aside for reassembly Remove the lamp Apply dielectric grease to the socket and install the new lamp Test the light for proper opera tion Reinstall the gasket and lens cover Lens Cover 95 MAINTENANCE Spark Plugs Spark Plug Recommendations CAUTION Using non recommended spark plugs can result in serious engine damage Alwavs use Polaris recommended spark plugs Refer to the specifications section beginning on page 124 for the recom mended spark plug tvpe and gap for vour vehicle Alwavs torque spark plugs to specification 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 ope
67. ks and fallen trees when possible If unavoidable use extreme caution and alwavs follow proper procedures as outlined in the owner s manual A WARNING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Skidding or sliding can cause loss of control If the tires regain traction unexpectediv the ATV could overturn HOW TO AVOID THE HAZARD On slipperv surfaces such as ice travel slowlv and use extra caution to reduce the chance of skidding or sliding out of control 29 SAFETV Operator Safetv A WARNING POTENTIAL HAZARD Operating the ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident or overturn HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast flowing water If it s unavoidable to enter water that exceeds the recommended maximum depth see page 65 travel slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Always test the brakes after Peru water If necessary apply them several times to let friction dry out the pads A WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN The ATV could collide with an obstacle or person resulting in severe injury
68. l d Repairs and diagnosis performed outside of an authorized dealer e Use of parts which are not authorized by POLARIS Maintenance Schedule The LSI engine owner is responsible for having all scheduled inspection and mainte nance services performed at the intervals specified in the 2006 and later owner s manual and to retain records of these services as having been performed These records should be transferred to each subsequent owner of the LSI engine POLARIS cannot deny a claim solely because there are no records of scheduled maintenance however a war ranty claim may be denied if the failure to perform the scheduled maintenance and inspection resulted in the failure of a warranted emission related part As a minimum the LSI engine owner is responsible for the scheduled inspection and maintenance of emissions related items as specified in the maintenance section of the owner s manual 134 WARRANTV California Emission Control Warrantv Statement Repair and Replacement of Emission Related Parts It is recommended that only LSI engine replacement parts which have been authorized and approved by POLARIS should be used in the performance of any warranty mainte nance or repairs of emission related parts These replacement parts will be provided at no charge if the part is still under warranty How to File a Warranty Claim Where to Get Warranty Service All repairs qualifying under this Limited Warranty must be performed by a dealer
69. l 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 70 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Kev gt Perform these operations more often for vehicles subjected to severe use E Emission related service Failure to conduct this maintenance will not void the emissions warranty but may affect emissions M Have an authorized Polaris dealer perform these services A WARNING Improperly performing the procedures marked with a W could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services Perform all services at whichever maintenance interval is reached first Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km Steering PreRide Make adjustments as need Op Tea no rt ed See Pre Ride Checklist gt Front suspension Pre Ride on page 52 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 D
70. lectric grease to the socket and install the new lamp NOTE Make sure the tab on the lamp locates properly in the housing 8 Reassemble the pod 92 MAINTENANCE Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward Use the following procedure to make the adjustment 25 ft 7 6 m 1 Position the vehicle on a level surface with the headlight approxi mately 25 ft 7 6 m from a wall Lock the parking brake 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 3 Start the engine Turn the headlight switch to high beam 4 Observe the headlight aim on the wall The most intense part of the headlight beam should be two inches 5 cm below the mark on the wall NOTE Include rider weight on the seat when measuring 5 The adjustment knob is located on the right side of the headlight pod Adjust the beam to the desired position by turning the knob either clockwise or counterclockwise 93 MAINTENANCE Lights Headlight Housing Replacement 1 Remove the two screws on the lower front corners of the headlight pod 2 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 mount
71. led by the ATV Mode 2 Trip Meter The trip meter records the miles traveled by the ATV on each trip if it s reset before each trip To reset the trip meter select the trip meter mode Press and hold the mode button override button until the total changes to 0 NOTE In the Rider Information Center the trip meter display contains a deci mal point but the odometer displays without a decimal point Mode 3 Hour Meter This mode logs the total hours the engine has been in operation Mode 4 Tachometer The engine RPM is displayed digitally NOTE Small fluctuations in the RPM from day to day may be normal because of changes in humidity temperature elevation and electrical loads 47 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The diagnostic mode is for informational purposes only Please return your ATV to your dealer for all major repairs As long as the gauge is in the diagnostic mode the wrench icon will remain lit To leave the diagnostic mode turn the key switch off and on NOTE Any movement of the tires will also take the machine out of the diag nostic mode To enter the diagnostics mode Turn the key switch off and wait 10 seconds Lock the parking brake Place the transmission in neutral Hold the mode reverse override button and turn the key switch on 5 Release the switch as soon as the display is activated Pe ae The initial screen display refers to the
72. linkage 50H 6M 310 500 Inspect lubricate adjust E Steering 50H 6M 310 500 JLubricate gt Front suspension 50H 6M 310 500 Lubricate gt Rear suspension 50H 6M 310 500 Lubricate Carburetor float 50H 6M 310 500 Drain bowl periodically and bowl prior to storage E Throttle Cable 50H 6M 310 500 Inspect adjust lubricate E JETC Switch replace if necessarv E Choke cable 50 H 6M 310 500 Inspect adjust lubricate E replace if necessary E Carburetor air 50 H 6M 310 500 Inspect duct for proper seal intake ducts flange ing air leaks gt Front hub bear 50H 6M 310 500 Inspect clean replace as ings if equipped needed Drive belt 50H 6M 310 500 Inspect adjust replace as needed Cooling system 50H 6M 310 500 Inspect coolant strength if applicable seasonally pressure test system yearly 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 72 Periodic Maintenance Chart MAINTENANCE Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km gt Engine oil and filter 100 H 6M 620 1000 Perform a break in oil change change at one month gt Oil tank vent hose 100 H 12M 620 1000 Inspect routing condition z Valve clearance 100 H 12M 620 1000 Inspect adjust E F
73. ll 27 watt Taillights 8 26 watts Brake Light 26 9 watts Instrument Cluster LCD Clutching Chart Altitude Shift Drive Clutch Driven Helix Weight Spring Clutch Spring Meters 0 1800 10 MH Blue Green Red 40 Feet 0 6000 PN 5630513 PN 7041157 PN 7041198 PN 5131446 242 1800 3700 10 WH Blue Green Red 40 6000 12000 PN 5630710 PN 7041157 PN 7041198 PN 5131446 242 Jetting Chart AMBIENT TEMPERATURE 6000 12000 ALTITUDE Solow 40 F ES Meters Feet elow 40 40 F and above Below 5 C 5 C and above 0 1800 0 6000 147 5 142 5 1800 3700 140 135 125 POLARIS PRODUCTS Part Number Description Engine Lubricant 2870791 Fogging Oil 12 oz Aerosol 2871281 Premium 4 Svnthetic OW 40 4 Cvcle Engine Oil qt 2871844 Premium 4 Svnthetic OW 40 4 Cvcle Engine Oil gal Gearcase Transmission Lubricants 2873602 Premium AGL Svnthetic Gearcase Lubricant qt 2873603 Premium AGL Svnthetic Gearcase Lube gal 2871653 Premium ATV Angle Drive Fluid 8 oz 2872276 Premium ATV Angle Drive Fluid 2 5 gal 2870465 Pump for Gallon Jug 2871654 Premium Demand Drive Hub Fluid 8 oz 2872277 Premium Demand Drive Hub Fluid 2 5 gal Coolant 2871323 60 40 Coolant gal 2871534 60 40 Coolant qt Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 2871322 P
74. losions or other similar causes beyond the control of Polaris If you have any questions regarding your warranty rights and responsibilities you should contact the Polaris Warranty Department at 1 763 417 8650 136 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 137 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 138 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 139 INDEX A Age Restrictions 12 Air Box Drain 90 Air Filter ss seaca a a aes 90 All Wheel Drive System 43 AWD Switch 0 43 AWD System LL 43 B Battery Charging Sealed 107 108 Conventional 103 Fluid Conventional 106 Installation 105 Removal 104 Storage 106 Belt Life eee as 4 BOOt xii sa sawt Ges Sab ae pats 11 Brake Fluid Main Brake Svstem 38 Brake Lever Auxiliarv 37 Brake Lever Service 37 Brake Svstems
75. lowly at first Select an open area that allows room to famil iarize yourself with vehicle operation and handling 4 Vary the throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 52 6 Pull only light loads 7 During the break in period change both the oil and the filter at 20 hours or one month PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and better performance Break in the clutches and belt by operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggressive acceleration and high speed operation dur ing the break in period 51 OPERATION Pre Ride Checklist A WARNING proper operating condition If a proper inspection is not done before each use severe injury or death could result Alwavs inspect the vehicle before each use to ensure it s in protective clothing Item Remarks Page Brake system lever travel Ensure proper operation oe Brake fluid Ensure proper level 38 Auxiliary brake Ensure proper operation 37 Front suspension Inspect lubricate if necessary 74 Rear suspension Inspect lubricate if necessary 74 Steering Ensure free operation Tires Inspect condition and pressure 88 Wheels fasteners Inspect ensure
76. m for extended periods the oil pump may lose its prime which could result in engine damage Always replace the oil and filter within a few hours of draining the oil Do not allow the vehicle to be without oil overnight Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 70 Always change the oil filter whenever changing oil 1 Position the vehicle on a level surface 2 Start the engine Allow it to idle for two to three minutes Stop the engine 3 Clean the area around the drain plug 4 Place a drain pan under the oil tank Remove the drain plug Allow the oil to drain com pletely 5 Install a new sealing washer on the drain plug NOTE The sealing surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches 6 Reinstall the drain plug Torque to 14 17 ft Ibs 19 23 Nm 7 Disconnect the lower oil delivery hose and remove the screen fitting from the oil tank Clean the fitting NOTE The fitting threads must be sealed with LOCTITE PST 505 or PTFE seal tape Alignment Mark 78 MAINTENANCE Oil and Filter Change 8 Reinstall the screen fitting and rotate the fitting clockwise a mini mum of 2 1 2 turns into the tank threads Continue to rotate the fit ting until the nipple of the fitting aligns with the mark on the tank NOTE Do not over tighten Maximum torque for the screen fitting is 25 ft Ibs
77. mber and serial 0006 31 number will also be displayed on the label 10 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 11 SAFETV Operator Safetv A WARNING Failure to follow the warnings 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 Read and understand vour owner s manual and all warnings before operating a Polaris ATV Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 1
78. med by an authorized Polaris dealer The emissions label is located on the recoil cover or stator housing Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 This vehicle complies with European directives 97 24 EC and 89 336 EEC 69 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 vour Polaris dealer Record maintenance and service in the Maintenance Log beginning on page 137 NOTE Service and adjustments are important for proper vehicle operation If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition 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 e Short trip cold weather operation Pay special attention to the oil leve
79. movement and return before starting the engine Also check occasionally during operation Engine speed and vehicle move ment are controlled by pressing the throttle lever The throttle lever is spring loaded Engine speed returns 7 to idle when the lever is released A Lae OD This ATV is equipped with Polaris Electronic Throttle Control ETC Pome e which is designed to reduce the risk of a frozen or stuck throttle If the throttle should stick in an open position engine RPM will diminish and power to the rear wheels will cease A A WARNING Modifications to the ETC could result in failure to perform as designed which could result in severe injurv or death Do not attempt to modifv the ETC svstem or replace it with anv after market throttle mechanisms Alwavs ensure that the throttle cable is properlv installed to the ETC 36 FEATURES AND CONTROLS Brake Svstems The braking svstem is controlled bv the two brake levers located on the handlebars Service Brake Lever The service brake lever is located on the left handlebar This lever controls both front and rear wheel braking action Use this lever for normal braking Apply the service brakes by squeezing the left brake lever toward the handlebar These brakes are hydraulically activated disc brakes Always test brake lever travel and check the reservoir fluid level
80. n authorized Polaris dealer Use the following procedure to check the toe alignment of the vehicle The recommended toe alignment is 1 8 to 1 4 3 6 mm toe out 1 Place the handlebars in a straight ahead position use gol 3 009 2 Place stands in front of ee the vehicle perpendicular Ci EN to the rear tires 7 Q 3 Tie an elastic string around the stands mak ing sure the string just touches the side surface String of the rear tires on each side of the vehicle and goes around the stands in front of the vehicle 4 Measure the distance from the string to the rim at the front and rear of the front rim Rear measure ment should be 1 16 to 1 8 2 3 mm more than Front of 22 the front measurement Front Rim NOTE If you discover improper alignment see your Polaris dealer for service Stands Rear of Front Rim y 80 999 ao AEEA avo gooo RS Qo ase 86 MAINTENANCE Steering Assemblv The steering assemblv of the ATV should be checked periodicallv 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 Remove the seat 2 Grasp the rear of the side panel near the rear cab With a quick and firm motion pull the panel forward and out ward to disengage the two rear tabs 3
81. n excessivelv rough slipperv or loose terrain could cause loss of traction or loss of control which could result in an accident or overturn HOW TO AVOID THE HAZARD Do not operate on excessivelv rough slipperv or loose terrain until vou ve learned and practiced the skills necessary to control the ATV on such terrain Always use extra caution on rough slippery or loose terrain A WARNING POTENTIAL HAZARD Turning improperiv WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn HOW TO AVOID THE HAZARD Alwavs follow proper procedures for turning as described in the owner s manual Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speed 25 SAFETV Operator Safetv A WARNING POTENTIAL HAZARD perang on excessively steep ills WHAT CAN HAPPEN The vehicle may overturn HOW TO AVOID THE HAZARD Never operate on hills too steep for the ATV or for your abilities Never operate the ATV on hills steeper than 15 degrees A WARNING POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner s manual Always check the terrain carefully before ascending any hill Never operate the ATV on hills steeper than 15 deg
82. n the housing before storing the vehicle Make sure the hous ing is completely dry before reinstalling the drain plug 1 Stop the engine 2 Place the transmission in gear 3 Lock the parking brake 4 Remove the drain plug on the bot tom of the recoil housing 5 Allow the housing to drain com pletely 6 Reinstall the drain plug S NOTE Do not open the crankcase drain 0 unless the engine has ingested i water On 4 cycle engines some engine oil will be lost if the crank case drain is opened 97 MAINTENANCE Vehicle Immersion CAUTION If your vehicle becomes immersed major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine 10 11 12 13 98 If it s impossible to take your ATV to a dealer before starting it fol low the steps outlined below Move the ATV to dry land or at the very least to water below the footrests Check the air box If water is present dry the air box and replace the filter with a new filter Turn the fuel valve off Remove the spark plug Loosen the carburetor drain screw Turn the engine over several times using the electric start Dry the spark plug Reinstall the plug or install a new plug Tighten the carburetor drain screw Turn the fuel valve on Drain Screw Attempt to start the engine If necessary repeat the drying pro cedure Take the ATV to
83. ng the button will allow the numbers to escalate much faster When the desired time increment is displayed release the button and wait for the wrench to stop flashing When the wrench stops blinking your service hours are set NOTE If you scroll past the intended number hold the button down until the count turns over to 0 You can then reset the number If the service interval is enabled on your ATV and you wish to turn it off toggle to the service interval mode Press and hold the mode button for approximately 7 seconds until the word OFF appears in the Rider Information Center Screen 6 Miles Kilometers toggle The display in the tripmeter and odometer can be changed to display either kilometers or miles The current display mode will be shown as KM or MP To change hold in the mode button until the letters flash then press and release the button once When the display stops flashing the mode has been set 49 OPERATION Fuel Safetv A WARNING Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always refuel with the engine stopped and outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and
84. ng the water stream at the follow ing items e Wheel bearings e Radiator Transmission seals e Brakes e Cab and body panels e Labels and decals NOTE If warning and safety labels are damaged contact your Polaris dealer for free replacement Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system Polishing the Vehicle 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 Avoid 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 110 MAINTENANCE Cleaning and Storage Storage Tips CAUTION 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 clean the vehicle as recommended See page 109 Fog the Engine 1 2 Support the front end of the machine so the engine is level or tilted slightly rearward Remove the spark plug Rotate the piston to BDC and pour two ounces 59 ml of Premium 4 Synthetic OW40 engine
85. nge 1 Position the vehicle on a level sur face Remove the propshaft shield from the right side of the vehicle 2 Place a drain pan under the gearcase 3 Remove the drain plug Allow the oil to drain completely Drain Plug 4 Clean the drain plug Install a new sealing washer on the drain plug 5 Reinstall the drain plug Torque to 14 ft lbs 19 Nm 6 Remove the fill plug Add the recommended oil See page 124 for capacities 7 Reinstall the fill plug Torque to 14 ft Ibs 19 Nm 8 Check for leaks 9 Reinstall the propshaft shield 10 Dispose of used oil properly 81 MAINTENANCE Front Gearcase Oil Alwavs check and change the front gearcase oil at the intervals outlined in the Periodic Mainte nance Chart beginning on page 70 Maintain the oil level at the bottom of the fill hole threads We recommend the use of Polaris Premium ATV Angle Drive Fluid See page 126 for the part numbers of Polaris products Oil Check 1 Position the vehicle on a level surface 2 Remove the fill plug 3 Check the oil level 4 Add the recommended gearcase oil as needed to bring the level to the bottom of the fill hole threads 5 Reinstall the fill plug Torque to 14 ft lbs 19 Nm Oil Change 1 Position the vehicle on a level surface 2 Remove the fill plug 3 Place a drain pan under the gearcase The drain plug is located on the bottom right hand side of the gearcase 4 Remove the dra
86. nnot be regained adjustments to the carburetor and drive system can be made to allow more efficient opera tion Optional jets available from your Polaris dealer are required for operation above 6 000 feet and temperatures below 40 degrees F 4 degrees C NOTE Continuous operation of the engine without proper jetting when required can cause poor performance overheating or PVT or engine damage See your Polaris dealer for more information about jetting the ATV for conditions in your area NOTE Pilot screws are sealed with metal plugs and are serviceable only by Polaris dealers Carburetor Engine Idle RPM Adjustment Recommended engine idle RPM is 1200 200 If the engine idle speed is unsatisfactory and all other conditions are favorable the carbu retor can be adjusted 1 Start the engine and allow it to warm up for approximately five minutes Place the transmission in gear 3 Lock the parking brake 4 Turn the screw in clockwise to raise RPM Turn the screw out counterclockwise to lower RPM Idle Screw 119 TROUBLESHOOTING Drive Belt Wear Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range during loading Starting out going up a steep incline Use low range or turn around using the K turn see page 64 Driving at low RPM or ground speed 3 7 MPH Drive ata higher speed or use low range more frequentiv See page 102 Insuffici
87. o AWD while the rear wheels are spinning may cause severe drive shaft and hub damage Always switch to AWD while the rear wheels have traction or are at rest 43 FEATURES AND CONTROLS All Wheel Drive AWD System Disengaging Wheel Hubs The hubs normally disengage when operating in reverse However one or both hubs may occasionally remain engaged If the handlebars pull to one side one front hub is engaged If both hubs are engaged steering effort increases but remains balanced from left to right and vehicle speed is somewhat restricted 1 Stop the vehicle and shift to reverse gear 2 Operate in reverse for a short distance 3 Stop the vehicle and shift to forward gear NOTE Ifthe hubs remain engaged after following this procedure return the vehicle to your dealer for service To continue using AWD while operating in reverse activate both the override switch and the AWD switch See page 34 A WARNING Operating with only one front hub engaged could result in loss of control accident and severe injury or death When hub engagement symptoms are present use the disengaging procedure before proceeding Tool Kit To help you perform routine maintenance a tool kit is provided in the storage compartment under the seat Items included in the kit are e Screwdriver e Open end wrench 8 10 mm e Open end wrench 12 14 mm e Box end wrench e Tire pressure gauge e Spark plug wrench and handle
88. o function properly Contact your dealer for the correct replacement part 7 Reinstall the front compartment 8 Secure the box cover 84 MAINTENANCE Brakes Rear Brake The transmission brake is a hvdrau lic disc brake This brake is acti vated by the left brake lever which also activates the front brakes The transmission brake system is self adjusting Periodically check the brake pads for wear Replace brake pads when they are worn to 3 64 1 mm 3 64 1 mm Periodically inspect the brake disc spline and pad wear surface for excessive wear Front Wheel and Middle Axle Brake The front wheel and middle axle brakes are hydraulic disc brakes These brakes are self adjusting and require no adjustment The following checks are recommended to keep the brake systems in good operating condition Check more often if brakes are used heavily under normal operation 1 Always keep brake fluid at an adequate level See page 38 2 Check the brake system for fluid leaks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness Replace brake pads when they are worn to 3 64 1 mm 5 Check the security and surface condition of the disc 85 MAINTENANCE Toe Alignment A WARNING Severe injurv 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 a
89. oil into the cylinder Reinstall the spark plug Torque to specification Apply dielectric grease to the inside of the spark plug cap Reinstall the cap Turn the engine over several times using the recoil starter Oil will be forced in and around the piston rings and ring lands coating the cylinder with a protective film of fresh oil Treat the fuel system with Polaris Carbon Clean See page 112 If Polaris fuel system additive is not used the fuel tank fuel lines and carburetor should be completely drained of gasoline 111 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels Change fluids as recommended in the Periodic Maintenance Chart beginning on page 70 Front demand drive unit front gearcase e Rear gearcase if equipped e Transmission e Brake fluid change every two years and any time the fluid looks dark or contaminated e Coolant test strength fill 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 NOTE Carbon clean will also reduce the possibility of bacterial growth in the fuel system 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the fuel in the tank Oil and Filter Change the oil and filter See page 78 Air Filter Air Box 1 Inspect and clean or replace the pre cleaner
90. oltage each month during storage and recharge as needed to maintain a full charge NOTE Power plug leads mav need to be bent down so that the batterv cover can be installed NOTE Batterv charge can be maintained bv using a Polaris Batterv 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 126 for the part numbers of Polaris products Batterv Fluid Conventional Batterv A poorlv maintained batterv Upper will deteriorate rapidly Check Lower Mark the battery fluid level often Mark 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 106 MAINTENANCE Batterv Batterv Charging Sealed Batterv 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 vol
91. on hills can result in loss of control or vehicle overturn resulting in severe injury or death Avoid crossing the side of a hill when possible Follow proper procedures as outlined in the owner s manual Sidehilling can dangerous and should be avoided if at all possible If you encounter a situation where sidehilling is necessary follow these precautions 1 Slow down 2 Shift your weight uphill 3 Keep your feet on the footrests 4 Steer slightly into the hill to maintain vehicle direction NOTE Ifthe vehicle begins to tip quickly turn the front wheel downhill if pos sible or dismount on the uphill side immediately 62 OPERATION Driving Safelv Driving Downhill A WARNING Excessive speed when traveling downhill can cause loss of control and serious injury or death Slow down Hard use of the braking system while descending a hill could result in a front end overturn causing serious injury or death Always operate the brakes slightly when descending a hill When driving downhill follow these precautions 1 Shift your weight uphill 2 Drive straight downhill 3 Slow down 4 Apply the brakes slightly to gradually slow the vehicle NOTE Before operating your ATV learn how to use the auxiliary brake for emergency situations if service brakes become inoperable 63 OPERATION Driving Safelv Turning Around on a Hill K Turn If the vehicle stalls while climbing a hill
92. oot 30 cm higher than the front Block the wheels 8 Place the transmission in neutral 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 99 MAINTENANCE PVT Svstem A WARNING Failure to complv with the instructions in this warning can result in severe injurv or death Do not modifv anv component of the PVT svstem Doing so mav reduce its strength so that a failure mav occur at a high speed The PVT svstem has been precision balanced Anv modification will cause the svstem to be out of balance creating vibration and additional loads on components The PVT svstem rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safetv of this product However as the owner vou 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 e Always make sure the PVT housing is securely in place during operation 100 MAINTENANCE PVT Svstem The basic operation of the Polaris PVT svstem is dependent on engine speed and vehicle torque requirements As
93. proper diagnosis Gear Indicator As 3 4 5 6 the shift lever is moved this indicates the gear the transmis sion is in H High Gear L Low Gear N Neutral R Reverse Gear P Park if equipped 1 AWD Indicator This indicator illuminates when the electrical por tion of the AWD system is enabled Engine Hour Display Indicator Service Interval Diagnostic Mode Indicator Low Battery and Over Voltage This warning usually indicates that the ATV is operating at an RPM too low to keep the battery charged A low battery warning may also occur under normal oper ation if the machine is at idle and high electrical load lights cool ing fan accessories is applied Driving at a higher RPM or connecting a battery charger will usually clear the warning Odometer Tachometer Tripmeter Hour Meter Check Engine Warning Indicator This indicator serves two pur poses The word HOT displays if the engine overheats Do not oper ate the ATV if this warning appears Serious engine damage could result Mode Indicator FEATURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes The rider information center has 4 standard modes The reverse override button on the left handlebar is also the mode button NOTE If using the mode button to program the rider information center or to toggle through the options the transmission cannot be in reverse Mode 1 Odometer The odometer records the miles trave
94. r door POLARIS The Way Out POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus tries Inc Copyright 2006 Polaris Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor 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 2007 Sportsman 6X6 Owner s Manual P N 9920775 2 TABLE OF CONTENTS Know Your Vehicle 0000 eee eee eee 5 Safety ie ss nbs Gente Ss See bid ig basis 6 Features id idee eae inne dais 34 Operation si ia iera a te ened 50 Emission Control Systems 69 Maintenance 2ssseneennnnnnnnn nn 70 Adjustments annennnn ena 115 Troubleshooting LL 120 Specifications 2 6 ncsaw ex ka kk 124 Polaris Products 00eeeeeees 126 Warranty 330 ete bce een 4 ORR eae es 127 Maintenance Log 000eeees 137 INDOX eves eee tee eae ee 140 KNOW VOUR VEHICLE As the operator of the vehicle vou are responsible for vour personal safety t
95. ration 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 plug for correct color See page 97 A WARNING A hot exhaust system and engine can cause serious 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 spark plug counterclockwise to remove it 3 Reverse the procedure for spark plug installation Torque to specifi cation 96 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 NOTE The tip should not be flakv and white A white insulator tip indicates overheating caused bv 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 Recoil Housing Always drain the recoil housing after operating the vehicle in wet condi tions Drai
96. ration abrasion or leaks Replace as needed 4 Reinstall the filter with the arrow pointing toward the air box Secure the hose clamps NOTE The breather filter is intended to be used with the air box pre filter in place Without the pre filter the breather filter can clog quickly CAUTION Operation of your vehicle without both the pre filter and breather filter can cause engine damage Always reinstall both filters after removing them for service 91 MAINTENANCE Lights 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 A WARNING Poor lighting while driving can result in severe injury or death Headlight and taillight lenses become dirtv during normal operation Wash the headlights frequently to maintain lighting quality Hot components can cause serious burns to skin Allow lamps to cool before servicing Headlight Lamp Replacement 1 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 tabs at the rear of the pod Lift the pod cover and disconnect the speedometer harnesses from the speedometer 5 Unplug the headlamp from the wiring harness Be sure to pull on the connector not on the wiring 6 Turn the lamp counterclockwise to remove it 7 Apply die
97. rees Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly while traveling uphill The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill 26 SAFETV Operator Safetv A WARNING POTENTIAL HAZARD Traveling downhill improperly WHAT CAN HAPPEN SEM Improperly descending a hill could cause loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner s manual NOTE A special technique is required when braking while traveling downhill See page 63 Always check the terrain carefully before descending a hill Shift your weight rearward Never travel down a hill at high speed Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when possible A WARNING POTENTIAL HAZARD Improperly crossing hills and turning on gt hills WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of control or overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around R on any hill until you ve mastered the p a turning technique on level ground as Tis described in the owner s manual See page 64 Use extra caution when turning on any hill
98. remium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 2871460 Starter Drive Grease 2 oz 2871515 Premium U Joint Lube 3 oz 2871551 Premium U Joint Lube 14 oz 2871329 Dielectric Grease Nyogel 2872073 Chain Lube Aerosol 6 25 oz 2872348 Chain Lube Aerosol 16 oz Additives Miscellaneous 2872889 Brake and Clutch Cleaner 2871326 Carbon Clean Plus 12 oz 2870652 Fuel Stabilizer 16 oz 2872189 DOT4 Brake Fluid 12 oz 2872893 Engine Degreaser 12 oz 2871956 Loctite 565 Thread Sealant 2871076 Polaris Battery Tender Charger 126 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 Light Utility Vehicle against defects in material or workmanship Polaris also gives a one year limited warranty on the final drive chain for failure due to defects This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transferable to another consumer during the warranty period through a Polaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty No verification of regi
99. rt 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 authorized Polaris dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to per form the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of the destination country before you move Vehicles importation rules vary considerably from country to country
100. rv sidewavs which could spill electrolvte A CAUTION If electrolvte spills immediatelv wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle 104 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 107 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 NOTE The vent tube must be free of obstructions and securely installed If not battery gases could accumulate and cause an explosion The tube should be routed away from the frame and body to prevent corro sion Avoid skin contact with electrolyte which can cause severe burns Connect and tighten the red positive cable first Connect and tighten the black negative cable last Install the battery cover Secure the battery hold down strap OO ON No ae Verify that cables are properly routed 105 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 v
101. ry 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 A WARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN 103 MAINTENANCE Batterv A WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last Battery Removal Disconnect the battery hold down strap Remove the battery cover On conventional batteries remove the battery vent tube Disconnect the black negative battery cable first Disconnect the red positive battery cable last DAR 03 NO Lift the batterv out of the ATV Be careful not to tip a conventional batte
102. s Never operate an ATV on a public street road or highway including a dirt or gravel road Never operate an ATV without wearing an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots a long sleeved shirt or jacket and long pants Never consume alcohol or drugs before or while operating an ATV Never operate at excessive speeds Travel at speeds appropriate for the terrain visibility and operating conditions and your experience Never attempt jumps or other stunts Always inspect your ATV before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and schedules outlined in your owner s manual Always keep both hands on the handlebars and both feet on the foot rests of the ATV during operation 15 SAFETV Operator Safetv 16 Always travel slowly and use extra caution when operating on unfa miliar terrain Be alert to changing terrain conditions Never operate on excessivelv rough slipperv or loose terrain Alwavs follow proper turning procedures as described in this manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speeds Alwavs have the ATV inspected bv an authorized Polaris dealer if it s been involved in an accident Never operate on hills too steep for the ATV or for vour abilities Practice on smaller hills before attempting larger hills
103. 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 a 1 Remove the left side panel a See page 87 Recover 2 Maintain the coolant level Bottle between the minimum and maximum marks on the bot tle when the fluid is cool 3 Add coolant as needed 9 83 MAINTENANCE Cooling Svstem Radiator Coolant To ensure that the coolant maintains its abilitv to protect the engine Polaris recommends that vou drain the svstem completelv everv two years and add a fresh mixture of antifreeze and water Replace the coolant any time the cooling system has been drained for maintenance or repair If the recovery bottle has run dry check the level in the radiator Add coolant as needed A WARNING Escaping steam can cause severe burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 1 Open the front box cover Screws 2 Using the tool provided remove the four screws securing the front compart ment to the vehicle 3 Place your fingers under the front of the compartment and pull upward to remove it 4 Remove the pressure cap 5 Using a funnel slowly add coolant through the radiator filler neck 6 Reinstall the pressure cap NOTE Use of anon standard pressure cap will not allow the recovery system t
104. se Follow these precautions when operating in reverse 1 Always check for obstacles or people behind the vehicle 2 Always avoid backing downhill 3 Back slowly 4 Apply the brakes lightly for stopping 5 Avoid turning at sharp angles 6 Never open the throttle suddenly 7 Never activate the override button while the throttle is open A WARNING Failure to use caution when operating in reverse can result in serious injury or death Before shifting into reverse always check for obstacles or people behind the vehicle When it s safe to proceed back slowly Do not use the override switch unless additional power is required for vehicle movement Use with caution Avoid backing on inclines and avoid turning at sharp angles NOTE Your Polaris ATV is equipped with a reverse speed limiter Use the override button with caution as rearward vehicle speed is greatly increased Do not operate at wide open throttle CAUTION Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust resulting in engine popping and or engine damage Operate the throttle just enough to maintain a desired speed 67 OPERATION Driving Safelv Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 Stop the engine Place the transmission in gear Lock the parking brake Always block the rear wheels on th
105. se or accidental starting FOR MORE INFORMATION ABOUT ATV SAFETY call the Consumer Product Safety Commission at 1 800 638 2772 or visit www cpsc gov visit www atvsafety org or call Polaris at 1 800 342 3764 17 SAFETV Operator Safetv Equipment Modifications We are concerned for the safety of our customers and for the general public Therefore we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury The warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power NOTE The addition of certain accessories including but not limited to mow ers blades tires sprayers or large racks may change the handling characteristics of the vehicle Use only Polaris approved accessories and familiarize yourself with their function and effect on the vehicle 18 SAFETV Operator Safetv A WARNING POTENTIAL HAZARD Operating this ATV without proper instruction WHAT CAN HAPPEN The risk of an accident is greativ increased if the operator does not know how to operate the ATV properly in different situations and a on different types
106. se risk of los ing control e USE ALCOHOL or DRUGS before or while operating this vehicle Operate at speeds too fast for your skills or the conditions e Operate this vehicle on HILLS steeper than 15 degrees To prevent flipover on hilly terrain use throttle and brakes gradually ALWAYS e Use an approved HELMET AND PROTECTIVE GEAR e Avoid paved surfaces Pavement may seriously affect handling and control e Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills and rough terrain and in turns e Use OVERRIDE for reverse speed limiter with caution To prevent loss of control never activate override button with open throttle REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent flipover avoid sharp turns PARKING BRAKE may relax when used for more than 5 minutes When parking on grades leave shift in forward LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS IF OWNER S MANUAL IS MISSING CONTACT A POLARIS DEALER FOR A REPLACEMENT SAFETV Safetv Decals and Locations Reverse Override Warning Front Rack Warning Tire Pressure Load Warning Tire Pressure Load Warning WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE IN PSI KPa FRONT 5 34 5 CENTER 5 34 5 REAR 5 34 5 MAXIMUM WEIGHT CAPACITY Gross Vehicle Weight INCLUDING MACHINE DRIVER AND CARGO
107. ss Needs charge with desulfating charger At least 20 hours 108 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 CAUTION 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 last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips e Avoid the use of harsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle 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 109 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 directi
108. stem Kinked or plugged fuel tank vent line Inspect and replace Low octane fuel Replace with recommended fuel Clogged fuel filter Replace filter Incorrect fuel Replace with recommended fuel Incorrect jetting Possible Rich Fuel Cause Fuel is very high octane See your Polaris dealer Solution Replace with lower octane fuel Overuse of choke Inspect clean and or replace spark plugs 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 Incorrect jetting See your Polaris dealer 122 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 Overuse of choke Inspect clean and or replace spark plugs Water is present in fuel Replace with new fuel Fouled or defective spark plug s Inspect clean and or replace spark plug s 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 Repla
109. stration 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 VEHICLE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehicle is very important in ensuring trou ble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage 127 WARRANTV WARRANTV COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warrantv excludes anv failures that are not caused bv a defect in material or workmanship This warrantv does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any vehicle that has been altered structurally neglected improperly maintained used for racing or used for purposes other than for which it was manufactured or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts com ponents or the vehicle due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unaut
110. t What is Covered Under This Warranty Repair and or replacement of any warranted emission related part will be performed at no charge provided the work is performed at an authorized dealer There will also be no charge for any diagnostic labor performed at an authorized dealer which leads to the determination that a warranted emission related part is defective Any warranted part which is not scheduled for replacement as required maintenance or which is scheduled only for regular inspection to the effect of repair or replace as nec essary shall be warranted for the warranty period Any warranted part which is sched uled for replacement as required maintenance shall be warranted for the period of time up to the first scheduled replacement of that part This warranty shall apply only towards the repair replacement and or adjustment of the component parts listed below Emission Related Parts Covered Under This Warranty 1 Fuel Metering System i Carburetor and internal parts and or pressure regulator or fuel injection system ii Air fuel ratio feedback and control system if applicable iii Cold start enrichment system if applicable iv Regulator assy gaseous fuel if applicable 2 Air Induction System 1 Intake manifold if applicable ii Air filter 3 Ignition System i Spark plugs ii Magneto or electronic ignition system iii Spark advance retard system if applicable 4 Exhaust manifold if applicable 5
111. tmeter or multimeter to measure DC voltage For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher 2 Ifthe voltage is less than 12 8 volts recharge the battery at 1 2 amps or less until battery voltage is 12 8 or greater NOTE When using an automatic charger refer to the charger manufacturer s instructions for recharging When using a constant current charger use the following guidelines for recharging A 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 107 MAINTENANCE Batterv Batterv Charging Sealed Batterv NOTE Alwavs verifv batterv condition before and 1 2 hours after the end of charging harge Tim State of e arge e Voltage Action Using constant current Charge charger standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 mos from date of manufacture None required 75 100 12 5 12 8 volts May need slight charge if no charge given check in 3 months 3 6 hours 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or le
112. tting on eccentric and grease with grease gun Locate fitting on swing arm and grease with grease gun Middle Axle Bearings Center Swing Arm Housing Rear Strut Tie Rod Ends Polaris Premium all Season Grease or grease conform ing to NLGI No 2 gt Locate fitting on eccentric and grease with grease gun gt Locate fitting on swing arm housing and grease with grease gun gt Locate fitting on rear strut and grease with grease gun gt Grease with grease gun gt Perform more often for vehicles subjected to severe use 74 MAINTENANCE Lubrication Recommendations Front Prop Shaft Voke Tie Rod Ends AWD Hubs Middle Axle Bearings Ball Joint 4 00 Position Rear Strut Rear Axle Bearing 75 MAINTENANCE Engine Oil Premium 4 Svnthetic Lubricant Polaris Premium 4 All Season synthetic engine oil has been specially formulated for use in Polaris 4 cycle engines It s a fully synthetic high performance multi viscosity oil designed to provide the ultimate in lubrication performance and protection See page 126 for the part num bers of Polaris products Premium 4 possesses unsurpassed film strength over the widest possible temperature range It resists viscosity and frictional breakdown in ambi ent temperatures from 40 F to 120 F 40 to 49 C Its excep tional frictional properties result in more efficient operation more power output
113. uel system 100H 12M 620 1000 Check for leaks at tank cap E lines filter pump replace lines every two years E Fuel filter 100 H 12M 620 1000 Replace yearly gt Radiator 100H 12M 620 1000 jInspect clean external if applicable surfaces gt Cooling hoses 100 H 12M 620 1000 jInspect for leaks if applicable gt Engine mounts 100 H 12M 620 1000 Inspect Exhaust muffler 100H 12M 620 1000 jInspect pipe l Spark plug 100 H 12M 620 1000 Inspect replace as needed E Ignition Timing 100 H 12M 620 1000 Inspect gt Wiring 100 H 12M 620 1000 Inspect for wear routing securitv applv dielectric grease to connectors subjected to water mud etc E Clutches drive 100 H 12M 620 1000 Inspect clean replace worn and driven parts E Shift selector 200 H 24M 1240 2000 Inspect replace as needed lubricant E Brake fluid 200 H 24M 1240 2000 Change every two years Spark arrestor 300 H 36 M 1860 3000 Clean out Idle speed Adjust as needed E Toe adjustment Inspect periodically adjust when parts are replaced gt Auxiliary brake Inspect daily adjust as E needed Headlight aim Adjust as needed 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 73 MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic
114. ve slowly Practice maneuvering and using the throttle and brakes on level surfaces OPERATION Driving Safelv Turning the Vehicle Your ATV is equipped with a solid rear axle which drives all rear wheels equally at all times This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly To turn steer in the direction of the turn leaning your upper body to the inside of the turn while sup porting your weight on the outer footrest This technique alters the st balance of traction between the rear wheels allowing the turn to be made smoothly The same leaning technique should be used for turning in reverse A WARNING Turning at sharp angles or at excessive speeds can result in vehicle overturn and lead to serious injury Avoid turning at sharp angles Never turn at high speeds 59 OPERATION Driving Safelv Driving on Slipperv Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel or during freez ing weather follow these p 1 2 recautions Slow down when enter ing slippery areas Engage AWD before wheels begin to lose traction Maintain a high level of alertness reading the i trail and avoiding quick sharp turns which can cause skids Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight for
115. ward CAUTION Severe damage to drive train may occur if the AWD is engaged while the wheels are spinning Always allow the rear wheels to stop spinning before engaging AWD or engage AWD before wheels begin to lose traction A WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control accident and serious injury or death e Never apply the brakes during a skid e Do not operate on excessively slippery surfaces e Always reduce speed and use additional caution 60 OPERATION Driving Safelv Driving Uphill Whenever traveling uphill follow these precautions Drive straight uphill Avoid steep hills 15 maximum Keep both feet on the footrests Shift your weight uphill Proceed at a steady rate of speed and throttle opening DYN GA DD ES Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle A WARNING Braking and handling are greatly affected when operating in hilly terrain Improper procedure could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 15 maximum Use extreme caution when operating on hills and follow proper operating procedures outlined in the owner s manual 61 OPERATION Driving Safelv Driving on a Sidehill Sidehilling A WARNING Improperly crossing hills or turning
116. water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Turn the fuel valve off whenever the vehicle is stored or parked A WARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas 50 OPERATION Break In Period The break in period for your new Polaris ATV is the first ten hours of operation or the time it takes to use the first two full tanks of gasoline No single action on your part is as important as following the proce dures for a proper break in Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components CAUTION Excessive heat build up during the first three hours of operation will damage close fitted engine parts and drive components Do not operate at full throttle or high speeds during the first three hours of use Lack of proper lubrication will cause serious engine damage Always check the oil level when refueling the vehicle Engine and Drivetrain Break in 1 Fill the fuel tank with gasoline See page 40 2 Check the engine oil level on the dipstick See page 77 Add oil if necessary to maintain the level between the full and add marks 3 Drive s
117. y Registra tion 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 ommend the use of Polaris engine oil 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty SPARK ARRESTOR Polaris warrants that the spark arrestor in this vehicle will meet the efficiency require ments of 43 CFR 8343 1 c for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with Polaris recommendations 129 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 expo

Polaris 9920775 Offroad Vehicle User Manual

Contents

Download Pdf Manuals

Related Search

Related Contents