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Polaris 9919412 Offroad Vehicle User Manual

1. 178 TROUBLESHOOTING Engine Runs Irregularly Stalls or Misfires Possible Cause Solution Fouled or defective spark plug Worn or defective spark plug wire Incorrect spark plug gap or heat range Loose ignition connections Kinked or plugged fuel tank vent line Old poor or non recommended fuel Electronic throttle control ETC malfunction Other mechanical failure 179 TROUBLESHOOTING Engine Runs Irregularly Stalls or Misfires Possible Lean Fuel Mixture Cause Solution Possible Rich Fuel Mixture Cause Solution 180 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Kinked or plugged fuel vent line Fouled or defective spark plug Worn or defective spark plug wire Incorrect spark plug gap or heat range Loose ignition connections Old poor or non recommended fuel 181 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Clogged dirty or wet air filter Inspect and clean or replace Electronic throttle control ETC malfunction See your Polaris dealer Other mechanical failure See your Polaris dealer Overheated engine Clean radiator screen and core if equipped Clean engine exterior See your Polaris dealer Engine Overheating Possible Cause Solution Debris lodged in screen Remove and clean the screen Plugged radiator Use a garden hose to flush any debris from the radiator fins NOTE High pressure washers can deform the radiator fins and reduce co
2. 81 Driving in Reverse 88 89 Driving on Slippery Surfaces 78 Driving Over Obstacles 85 Driving Procedures 76 Driving Safely 76 89 Driving Through Water 86 87 Driving Uphill 79 E Electrical Switches 48 49 Electronic Throttle Control 53 Emissions Warranty 193 194 E Engine Cooling System 113 Engine Oil Level 103 104 Equipment Modifications 23 Exhaust Emission Control 91 F Foot Brake 2 c0 0244 ead e ead 54 Fuel Filter esien 60 Fuel Safety 67 Fuel Tank 60 Fuel Valve 0005 61 H Handlebars 152 Headlight Adjustment 119 Headlight Assembly Replacement 118 Headlight Lamp Replacement 117 I J K Instrumentation 50 Jetting Chart 185 Kelu Saal git a SS 82 Light Switches Lubrication Recommendations Maintenance Chart Maintenance Log Maintenance Record Maintenance Schedule Master Cylinder Oil Filter Change Oil Pump Priming Operator Restrictions Operator Safety P Parking Brake 58 59 Parking on an Incline 84 Polaris Products 183 Polishing the Vehicle 170 Pre Ride Inspection 70 71 R Reverse Lock Out Switch 65 S Safe Riding Gear 12 13 Safety Decals and Locations 8 11 Safety Training 15 Shift Pedal Serris
3. 11 SAFETY Safe Riding Gear Always wear appropriate clothing when riding an ATV Wear protective clothing for comfort and to reduce the chance of injury 1 Helmet Wearing a helmet can prevent a severe head injury Whenever riding a Polaris vehicle always wear a helmet that meets or exceeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has granted approval The 051039 approval number and serial number will also be 0006 031 displayed on the label 12 SAFETY Safe Riding Gear 2 Eye Protection 4 Clothing Do not depend on eyeglasses or sunglasses Always wear long sleeves and long pants to for eye protection Whenever riding a protect arms and legs Riding pants with Polaris vehicle always wear shatterproof kneepads and a jersey with shoulder pads goggles or use a shatterproof helmet face provide the best protection shield Polaris recommends wearing 5 Boots approved Personal Protective Equipment PPE bearing markings such as VESC 8 The best footwear is a pair of sturdy V 8 Z87 1 or CE Make sure protective over the calf boots with low heels eye wear is kept clean 3 Gloves Off road style gloves with knuckle pads are the best for com
4. 139 MAINTENANCE AND LUBRICATION Tires 4 amp WARNING 140 Operating your ATV with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death Maintain proper tire pressure as described on the ATV decal and in the owner s manual Always use original equipment size and type when replacing tires Make sure the wheels are installed properly Always replace tires when the tread depth measures 1 8 3 mm or less MAINTENANCE AND LUBRICATION Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less See illustration Wheel Removal 1 2 3 Stop the engine place the transmission in gear and lock the parking brake Loosen the wheel nuts slightly Elevate the side of the vehicle by placing a suitable stand under the frame Remove the wheel nuts and remove the wheel 1 8 3 mm 141 MAINTENANCE AND LUBRICATION Wheel Installation 4 amp WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Never install the rim with the valve stem to the inside of the vehicle Always ensure that all nuts are torqued to papas 1 Place the transmission in gear and lock the parking brake 2 Place the wheel on the wheel hub with the valve stem 1 toward the outside and rotation arrows
5. The clutch lever is located on the left hand handlebar Squeeze the clutch lever toward the handlebar to disengage the clutch Disengage the clutch before shifting gears FEATURES AND CONTROLS Foot Brake The foot brake 1 operates the rear brakes It s located in front of the right hand footpeg 2 If the rear wheels slide while using the foot brake reduce brake pedal pressure to brake the wheels without skidding Check the brake fluid level frequently for the foot brake system The reservoir is located under the seat Maintain the fluid level between the minimum and maximum marks Check the rear brake light for proper operation before each use of the vehicle See page 120 4 amp WARNING Aggressively applying the foot brake when backing down a hill may cause rear tipover which could result in serious injury or death Use caution when applying the foot brake Do not aggressively apply the foot brake when going forward The rear wheels may skid and slide sideways causing loss of control and serious injury or death 54 FEATURES AND CONTROLS Brake Lever The brake lever operates the front brakes It s located on the right handlebar Squeeze the brake lever toward the handlebar to engage the front brakes These brakes are hydraulically activated disc type brakes Always test brake lever travel and master cylinder fluid level before riding When squeezed the lever should feel firm Any sponginess would indicat
6. Never mix oil brands 102 MAINTENANCE AND LUBRICATION Engine Oil Level Check the oil level before each use of the vehicle The dipstick 1 is located on the left side of the ATV 1 Position the ATV on a level surface 2 Start the engine and let it idle for one minute 3 Stop the engine and remove the dipstick Wipe it dry with a clean cloth 4 Reinstall the dipstick completely NOTE The dipstick must be screwed completely in to keep the angle and depth of the stick consistent 5 Remove the dipstick and check the oil level Maintain the oil level in the safe range 2 between the full and add marks Do not overfill 6 Reinstall the dipstick MAINTENANCE AND LUBRICATION Engine Oil Level If the ATV is used year round check the oil level frequently A rising oil level could indicate the accumulation of contaminates such as water or excess fuel in the bottom of the oil tank Water in the bottom of the tank can lead to engine damage and must be drained Water accumulation increases as outside temperature decreases 104 MAINTENANCE AND LUBRICATION Oil and Filter Change CAUTION If the ATV is left without oil in the system for extended periods the oil pump may lose its prime which could result in engine damage Do not allow the vehicle to be without oil and filter overnight Always replace the oil and filter within a few hours of draining the oil Always change the oil at the intervals outlined in the Periodic M
7. cable first When reinstalling the battery always connect the negative cable last 134 MAINTENANCE AND LUBRICATION Battery Storage When the vehicle is placed in storage for three months or more the battery should be removed and stored out of the sun in a cool dry place Test and recharge the battery monthly and before reusing Battery Removal 1 Remove the front cab see page 121 and disconnect the strap securing the battery 2 Disconnect the black negative cable first then disconnect the red positive cable 3 Lift the battery out of the ATV 135 MAINTENANCE AND LUBRICATION Battery Installation 1 Place the battery in the battery holder 2 Connect and tighten the red positive cable first then connect and tighten the black negative cable 3 Attach the hold down strap and reinstall the front cab 4 Verify that cables are properly routed NOTE When installing a new battery make sure it s fully charged prior to its initial use Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance 136 MAINTENANCE AND LUBRICATION Battery Charging Sealed Battery The battery included with your ATV is sealed and the sealing strip cannot be removed Use a voltmeter or multimeter to measure DC voltage A fully charged battery will register 12 8 V or higher If the voltage is less than 12 8 volts recharge the battery Use the remote
8. repair or re placement of any defective materials components or products THE REMEDIES SET FORTH IN THIS LIM ITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSE QUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHER WISE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR 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 war ranty lasts so the above limitation may not apply if it is inconsistent with the controlling state law This limited warranty excludes failures not caused by a defect in material or workmanship 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 com petition This limited warranty also does not cover physical damage corrosion or defects caused by fire explo sions or other similar causes beyond the control of Polaris If you have any questions regarding your warranty rights and responsibilities you should
9. altitude and or temperature changes If the vehicle is to be operated at various altitudes and temperatures certain adjustments can be made to improve its operation and driveability Above 6000 feet 1800 m the engine air fuel mixture becomes overly rich An engine loses approximately 3 of its power for each 1000 foot 305 m increase in elevation Although this power cannot be regained changes to the carburetor and drive system can be made to allow more efficient operation NOTE Contact your dealer for altitude adjustments Your dealer has the training and special tools required to perform these modifications 166 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 167 CLEANING AND STORAGE Washing 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
10. an obstacle or person resulting in severe injury HOW TO AVOID THE HAZARD Before shifting into reverse gear always check for obstacles or people behind the ATV When it s safe to proceed back slowly SAFETY Operator Safety 4 amp WARNING Operating a damaged ATV can result in an accident with serious injury or death After any overturn or accident have a qualified service dealer inspect the entire machine for possible damage including but not limited to brakes throttle and steering systems 4 amp WARNING Safe operation of this rider active vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control which could result in severe injury or death CAUTION Exhaust system components are very hot during and after use of the vehicle Hot components can cause serious burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system Use caution when traveling through tall grass especially dry grass 47 FEATURES AND CONTROLS Engine Electrical Switches 1 Start Button The start button engages the starter Always release the start button as soon as the engine starts 2 Engine Stop Switch The purpose of this switch is to provide the operator with a quick means of engine shutdown in case of an emergency The engine will not start or run when
11. basis SAFETY If you purchased a used Polaris ATV you can take the ATV RiderCourseS 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 Follow the recommended maintenance program outlined in your owner s manual This program is designed to ensure that all critical components on the ATV are thoroughly inspected at specific intervals 15 SAFETY Operator Safety The following two pages identify signal words and symbols that appear in this manual Your safety is involved when these words and symbols are used Become familiar with their meanings before reading the manual The safety alert symbol on your vehicle or in this manual alerts you to the potential for personal injury 4 amp WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death 16 SAFETY Operator Safety 4 CAUTION The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle NOTE A note will alert you to important information or instructions SAFETY Operator Safety 4 amp WARNING Serious injury or death ca
12. in the past This category S Sport ATV is a high performance vehicle for off road use only in sport type recreation and competitive use by operators with advanced skills and substantial experience 10 Discretionary Warning 4 WARNING e Never operate this vehicle on HILLS steeper than 25 degrees lt lt 25 To prevent flipover on hilly terrain when going up or down use throttle and brakes gradually e REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent flipover avoid sudden braking or sharp turns e PARKING BRAKE may relax when used for more than 5 minutes When parking on grades leave ATV in gear Safety Decals and Locations No Passenger Warning 5 WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH SAFETY Tire Pressure Load Warning 6 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 REAR 5 34 5 MAXIMUM WEIGHT CAPACITY Gross Vehicle Weight INCLUDING MACHINE DRIVER AND CARGO IS 660 LBS 299 kg Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your risk of losing control For stability on rough or hilly terrain reduce speed and cargo Read Owner s Manual for more detailed loading information
13. off whenever the ATV is stored or parked e Make sure the vent line is in good condi tion and is routed properly 67 OPERATION Break In Period Careful treatment of a new engine and transmission will result in more efficient performance and longer life for both The break in period for your new Polaris ATV is defined as the first one hour of operation or the time it takes to use the first full tank of gasoline Follow the break in period with an additional two hours of cautious operation No single action on your part is as important as following the procedures for a proper break in Perform the following procedures carefully CAUTION Excessive heat build up during the first three hours of operation may damage close fitted engine and transmission parts Do not operate at full throttle or high speeds for extended periods during the first three hours of use Use of any lubricants other than those recommended by Polaris may cause serious engine damage We recommend the use of Polaris lubricants for your vehicle 68 OPERATION Break In Period 1 2 Fill the fuel tank with gasoline See page 60 Check the oil level on the dipstick See page 103 Add oil if necessary to maintain the level between the safe and add marks Allow the engine sufficient time to warm up before operating Drive slowly at first Select an open area that allows room to familiarize yourself with vehicle operation and handling Vary the throttle pos
14. resulting in severe injury or death Never run an engine in an enclosed area CAUTION Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating 1 Place the transmission in neutral lock the parking brake and disengage the clutch 2 Make sure the fuel valve is on 72 OPERATION Starting a Cold Engine 3 Sit on the ATV Pull the choke knob 1 out until it stops NOTE NOTE If the knob doesn t stay where positioned increase the tension by rotating the tension adjusting nut clockwise FULL ON P HALF ON Pq OFF ii The choke can be adjusted gradually depending on how much choke is needed for starting Be sure the choke is off during operation as excess fuel washing into the engine oil will increase wear on engine components 4 Move the engine stop switch to RUN 5 Turn the ignition key to ON 73 OPERATION Starting a Cold Engine NOTE If starting the engine while in neutral the neutral indicator light should be on If it isn t disengage the clutch and shift the foot pedal to find neutral See page 63 If starting the engine while in gear apply the hand brake and squeeze the clutch lever fully to disengage the clutch 6 Press the start button to start the engine Activate the starter for a maximum of five seconds Release the start button immediately when the engine starts NOTE Do not press the throttle lever w
15. se were set 63 Shifting Gears 64 Side Panel Removal 121 Spark Arrestor Clean Out 128 130 Spark Plugs 123 127 Specifications 184 185 Spring Preload Front 156 157 Spring Preload Rear 161 Starting a Cold Engine 72 74 Starting a Warm Engine 75 Steering Assembly 153 INDEX S Storage Recommendations 171 174 Suspension Front 154 157 Suspension Rear 158 162 Suspension Set Up Front 154 155 Suspension Set Up Rear 158 159 T Throttle Cable Freeplay 164 Throttle Lever 52 53 Tires eson y mena em ge oe 140 141 Toe Alignment 148 149 Transporting the ATV 175 Turning Around on a Hill 82 83 Vv Vehicle Identification Numbers 6 7 Vehicle Immersion 131 133 WwW Washing the Vehicle 167 169 Wheel Installation 142 Wheel Nut Torque 143 Wheel Removal 141
16. the ATV on such terrain Always use extra caution on rough slippery or loose terrain SAFETY Operator Safety 4 amp WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner s manual Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speed 4 amp WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle may overturn HOW TO AVOID THE HAZARD Never operate on hills too steep for the ATV or for your abilities Never operate the ATV on hills steeper than 25 degrees lt lt 25 Practice on smaller hills before attempting large hills 37 SAFETY Operator Safety 4 amp WARNING 38 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 25 Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly while traveling uphill The ATV could flip over backwards Never go over the top of any hill at high s
17. the switch is in the OFF position 3 Main Key Switch To start the engine the main key switch must be in the RUN position OFF RUN OFF ja 2 NOTE Both the main switch and the emergency engine stop switch will shut off all electrical power to the vehicle including lights To stop the engine quickly slide the stop switch either right or left to the OFF position CAUTION Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death Always remove the ignition key when the vehicle is not in use 49 FEATURES AND CONTROLS Instrumentation An illuminated light in the indicator window will alert you to the following conditions 1 Hot engine 1 2 3 2 Reverse gear is selected 3 Neutral gear is selected 50 FEATURES AND CONTROLS Lights 4 amp 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 The light switch is located on the left handlebar It s used to turn the lights on and off and to switch the lights from G HI to LO NOTE The lights won t work unless the key is in the ON position wa stop switch is in the RUN position 51 FE
18. uphill side of the ATV 40 SSN a CAS A SoS SAFETY Operator Safety 4 amp WARNING POTENTIAL HAZARD Stalling rolling or improperly dismounting while climbing a hill WHAT CAN HAPPEN The vehicle could overturn HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill If all forward speed is lost Keep your ae weight uphill Apply front brakes gradually When fully stopped apply rear brake as S7 Sen well then lock the parking brake a pee If the ATV begins rolling backwards Keep weight uphill Never apply engine power Never apply the rear brake while rolling backwards Apply the front brake gradually When fully stopped apply the rear brake as well and then lock the parking brake Dismount on uphill side or to either side if ATV is pointed straight uphill Turn the ATV around and remount following the procedure described in the owner s manual See page 82 41 SAFETY Operator Safety 4 amp WARNING 42 POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles _ Avoid operating over large obstacles such as rocks and fallen trees when possible If unavoidable use extreme caution and always follow proper procedures as outlined in the owner s manual WARNING POTENTIAL HAZARD Skidding or sliding WHAT
19. warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power NOTE The addition of certain accessories may change the handling characteristics of the vehicle Use only Polaris approved accessories and familiarize yourself with their function and effect on the vehicle 23 SAFETY Operator Safety 4 amp WARNING 24 POTENTIAL HAZARD Operating this ATV without proper instruction WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the ATV RiderCourse offered by Polaris through the SVIA They should then regularly practice the skills learned in the course and the operating techniques described in the Owner s Manual For more information about the ATV RiderCourse contact ATV Enrollment Express at 800 887 2887 or visit www atvsafety org SAFETY Operator Safety 4 amp WARNING POTENTIAL HAZARD Failure to follow the skill and experience recommendations for this ATV WHAT CAN HAPPEN Severe injury and or death could occur if a beginner or inexperienced driver operates this ATV HOW TO AVOID THE HAZARD Only operators with advanced skills and substantial experience should operate this ATV
20. 0 12 ft Ibs 14 16 Nm then torque the rear two bolts A gap of up to 1 8 3 mm will remain at the rear bolts 152 ADJUSTMENTS Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts If loose nuts and bolts are found or if you notice any freeplay in the steering post see your Polaris dealer for service before operating the vehicle Camber and Caster The camber and caster are non adjustable 153 ADJUSTMENTS Front Suspension Suspension Set Up 1 Position the vehicle on a level surface 2 Stop the engine 3 Elevate the front of the vehicle by placing a suitable stand under the frame NOTE The tires should be barely touching the ground and the suspension should be at full rebound 4 Measure the distance from the ground to the bottom of the lower front bumper bolt Note this measurement for later use 5 Remove the stand and have a rider sit comfortably on the seat with hands on the handlebars 154 ADJUSTMENTS Front Suspension Suspension Set Up 6 Place the transmission in neutral and slowly roll the machine forward and rearward at least ten feet 3 m without lifting or pushing down on the suspension 7 Turn the handlebars fully to the left and right 8 With the rider still on the vehicle repeat the measurement performed in step 4 9 Subtract the step 8 measurement from the step 4 measurement The difference should be b
21. 000 4800 Front and rear wheel 300 H 36 M 3000 4800 Inspect replace as needed bearings espesa sewa gt po S Toe adjustment As required Periodic inspection adjust when parts are replaced Fenman areara __ __ Adjustas needed p Perform these procedures more often for vehicles subjected to severe use E Emission Related Service Have an authorized Polaris dealer perform these services Polaris Premium All Season Grease 101 MAINTENANCE AND LUBRICATION Lubrication Recommendations Performance Synthetic 4 Stroke PS 4 Oil Polaris highly recommends the use of Polaris PS 4 or a similar oil designed for use in 4 stroke manual clutch ATV and motorcycle applications PS 4 has been specifically formulated for use in high performance engines PS 4 is a fully synthetic high performance multi viscosity oil designed to provide the ultimate in lubrication performance and protection and prolonged clutch life See page 183 for the part numbers of Polaris products PS 4 oil possesses unsurpassed film strength over the widest possible temperature range It resists viscosity and frictional breakdown in ambient temperatures from 40 F to 120 F 40 to 49 C Its exceptional frictional properties result in more efficient operation more power output and lower fuel consumption CAUTION Mixing brands or using a non recommended oil may cause serious engine damage Polaris recommends the use of Polaris PS 4 oil
22. 2 on the tire pointing toward forward rotation 3 Install the wheel nuts and finger tighten 4 Lower the vehicle to the ground 5 Torque the nuts to specification See page 143 142 MAINTENANCE AND LUBRICATION Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loosened for maintenance service Front 3 8 30 35 ft Ibs 40 47 Nm Rear 3 8 30 35 ft Ibs 40 47 Nm 143 MAINTENANCE AND LUBRICATION Boot Inspection Before Operating Inspect the boots before operating the vehicle Ifa boot is torn punctured or leaking fluid see your Polaris dealer for service or replacement After Operating Inspect the boots after operating the vehicle If a boot is bulging or ballooned perform the boot burping procedure on page 145 Bulging Boot 144 MAINTENANCE AND LUBRICATION Boot Burping 1 Using a needle nose pliers or boot clamp removal tool remove the small boot clamp 1 from the inboard boot NOTE Do not use any tools that may damage the boot 2 Slide the free end of the boot two inches toward the center of the vehicle and lift the boot away from the shaft to allow excess air to escape 3 Wipe excess grease from the shaft before returning the boot to the boot groove Use caution not to allow excess air back into the system when reinstalling the boot 4 Reinstall the boot clamp 145 ADJUSTMENTS Brakes Under normal operation the diaphr
23. 2007 G POLARIS Owner s Manual The Way Out for Maintenance and Safety Pe eS MPLA This Category S Sport ATV is a high performance ATV for off road use only It is for sport type recreational and competitive use by operators with advanced skills and substantial experience Operation is prohibited for anyone under 16 years of age Read this manual carefully It contains important safety information AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS es POLARIS The Way Out NEVER e Operate without proper training or instruction e Operate on public roads A collision can occur with another vehicle e Operate at speeds too fast for your skills or conditions e Use ALCOHOL or DRUGS before or while operating this vehicle e Carry Passengers ALWAYS e Avoid paved surfaces which may adversely affect handling and control e Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills on rough terrain and in turns e Wear eye protection helmet and protective apparel For r your nearest Polaris dealer call 1 www polarisindustries com olaris Sales Inc 2100 pee vy 55 I MECINA Part No 9 20783 Re v 01 AWARNING The engine exhaust from this product contains chem
24. 25 SAFETY Operator Safety 4 amp WARNING 26 POTENTIAL HAZARD Failure to follow the age recommendations for this ATV WHAT CAN HAPPEN Severe injury and or death could occur if a child under the minimum age recommendation operates this ATV Even though a child may be within the recommended age group for operating some ATVs he she may not have the skills abilities or judgment needed to operate an ATV safely and could be susceptible to accident or injury HOW TO AVOID THE HAZARD No one under the age of 16 should operate a Polaris ATV Only operators with advanced skills and substantial experience should operate this ATV SAFETY Operator Safety 4 amp WARNING POTENTIAL HAZARD Carrying a passenger on an ATV WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator s ability to balance and control the ATV which could cause an accident and injury to the operator and or passenger HOW TO AVOID THE HAZARD Never carry a passenger The purpose of the long seat is to allow the operator to shift position as needed during operation It is not intended for carrying passengers 27 SAFETY Operator Safety 4 amp WARNING 28 POTENTIAL HAZARD Operating an ATV on paved surfaces including sidewalks paths parking lots and driveways WHAT CAN HAPPEN ATV tires are designed for off road use Operating on paved surfaces may adversely affect the handling of the ATV and could result in loss of contro
25. 7 6 m from a flat wall Measure the distance from the floor to the center of ol the headlight and make a mark on the wall at the O 9 Vz aa high beam Observe the headlight aim on the wall The most intense part of the headlight beam should be aimed 2 5 cm below the mark placed on the wall NOTE Include rider weight on the seat when measuring 5 6 same height Start the engine and turn the headlight switch to Loosen the pivot screw 1 and adjust the beam to the desired position Tighten the screw and torque to 27 in lbs 3 Nm 119 MAINTENANCE AND LUBRICATION Lights Brake Light Adjustment Check the rear brake light for proper operation before each use of the vehicle 2 1 Turn the ignition key on 2 Lightly apply and release the foot brake several times A properly operating rear brakelight will immediately flash on 3 and off with each movement of the brake pedal 3 Ifthe light does not operate properly grasp the switch body 1 with a pliers or similar tool and hold it lightly but securely Using a wrench rotate the adjustment nut 2 clockwise to increase tension on the spring 3 NOTE Rotate the adjusting nut counter clockwise to decrease tension on the spring if the brake light comes on when there is no pressure on the brake pedal 4 Recheck and readjust as needed until the brake light operates properly 120 Front Cab Removal 1 Side Panel Removal 1 2 3 MAINTENANC
26. ATURES AND CONTROLS amp WARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death Never start or operate an ATV with a sticking or improperly operating throttle Always contact your dealer for service if throttle problems arise Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation Always check the lever for free movement and return before starting the engine Also check occasionally during operation Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle lever 1 toward the handlebar The throttle lever is spring loaded Engine speed returns to idle and the ATV will slow down when the lever is released 52 FEATURES AND CONTROLS Throttle Lever Electronic Throttle Control This ATV is equipped with Polaris Electronic Throttle Control ETC which is designed to reduce the risk of a frozen or stuck throttle If the throttle cable should stick in an open position when the operator releases the throttle lever the engine will stop and power to the rear wheels will cease 4 WARNING The Electronic Throttle Control ETC stops the engine in the event of a throttle system malfunction and is provided for your safety Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms Clutch Lever
27. Avoid turning at sharp angles NOTE This Polaris ATV is equipped with a reverse speed limiter Do not operate at full throttle Use just enough throttle to maintain a desired speed CAUTION Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust resulting in engine popping and or engine damage 89 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine intake or exhaust components as doing so may affect compliance with U S A EPA noise control requirements 40 CFR 205 and local noise level requirements Operation on Public Lands in the U S A Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100 1C Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public lands in the U S A is regulated by 43 CFR 8343 Violations are subject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov ecfr Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 This vehicle complies with European directives 97 24 EC and 89 336 EEC 90 EMISSION CONTROL SYSTEMS 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 exh
28. CAN HAPPEN Skidding or sliding can cause loss of control If the tires regain traction unexpectedly the ATV could overturn HOW TO AVOID THE HAZARD On slippery surfaces such as ice travel slowly and use extra caution to reduce the chance of skidding or sliding out of control SAFETY Operator Safety amp WARNING POTENTIAL HAZARD Operating the ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident or overturn HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast flowing water If its unavoidable to enter water that exceeds the recommended maximum depth see page 87 travel slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Always test the brakes after leaving water If necessary apply them several times to let friction dry out the pads 43 SAFETY Operator Safety 4 amp WARNING 44 POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires or operation of the ATV with improper or uneven tire pressure could cause loss of control or accident HOW TO AVOID THE HAZARD Always use the size and type of tires specified for the ATV in the owner s manual A
29. DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law 188 WARRANTY HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service you must take it to a Polaris dealer authorized to repair Polaris ATVs When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR 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 personnel at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Engine Oil 1 Mixing oil brands or using non recommended oil may cause engine damage We recommend the use of Polaris engine oil 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty SPARK ARRESTOR Polaris warrants that the spark arrestor in this v
30. E AND LUBRICATION A y IN N LEE a Remove the screws 1 from the left and right cab mounts Remove the wire harness connector from the cab The connector is located under the left fender Remove the fuel tank cover screws 2 Remove the four side panel screws 3 R Gently pull the cab upward to disengage it from the stand off N Place the cab upside down on a soft protective surface to prevent scratching Unlatch and remove the seat Remove the front cab Remove the two screws 1 securing the side panel Remove the side panel 121 MAINTENANCE AND LUBRICATION Rear Cab Removal 1 Unlatch and remove the seat 2 Remove the two lower bolts 1 on the rear fenders of the cab and the two bolts 2 washers and grommets 3 on the top of the cab 3 Remove the cab 122 MAINTENANCE AND LUBRICATION Spark Plugs e Use NGK DCPR8E spark plugs e Proper electrode gap is 035 90 mm e Spark plug torque is 14 ft Ibs 19 Nm CAUTION Using non recommended spark plugs may result in serious engine damage and may void your emission related warranty Always use Polaris recommended spark plugs Spark plug condition is indicative of engine operation The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color 4 amp WARNING A hot exhaust system and engine can cause
31. Failure to heed these warnings could result in serious injury or death MAINTENANCE AND LUBRICATION Spark Arrestor Clean Out Periodically clean the spark arrestor to remove accumulated carbon Your vehicle has either an end cap type arrestor or a set screw type arrestor Perform the appropriate clean out procedure for your arrestor type End Cap Type Arrestor 1 2 Remove the three screws 1 and remove the arrestor 2 from the end of the muffler Use a non synthetic brush to clean the arrestor screen 3 A synthetic brush may melt if components are warm If necessary blow debris from the screen with compressed air Inspect the screen for wear and damage Replace a worn or damaged screen Remove and inspect the gasket 4 Replace a worn or damaged gasket Reinstall the gasket and arrestor Torque screws to 50 in Ibs 5 6 Nm 129 MAINTENANCE AND LUBRICATION Spark Arrestor Clean Out Set Screw Type Arrestor 1 Remove the bolt 1 and remove the arrestor 2 from the end of the muffler 2 Use anon synthetic brush to clean the arrestor screen 3 A synthetic brush may melt if components are warm If necessary blow debris from the screen with compressed air 3 Inspect the screen Replace the arrestor if the screen is worn or damaged 4 Reinstall the arrestor Torque the bolt to 7 ft Ibs 9 5 Nm 130 MAINTENANCE AND LUBRICATION Vehicle Immersion If your ATV has been submerged or overturned
32. ON Major engine damage can result if the vehicle is not thoroughly inspected after operation in water Perform the services outlined in the maintenance chart If your vehicle becomes immersed or is operated in water that exceeds the footpeg level take it to your dealer for service before starting the engine NOTE Avoid operating the vehicle through deep or fast flowing water If you cannot avoid water that exceeds the recommended maximum depth go slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes If your vehicle becomes immersed and it s impossible to take it to a dealer before starting it follow the steps described on page 131 Have the vehicle serviced by your dealer at the first opportunity 87 OPERATION Driving Safely Driving in Reverse Follow these precautions when operating in reverse 1 Avoid backing downhill 2 Back slowly 3 Apply the brakes lightly for stopping 4 Avoid turning at sharp angles 5 Never open the throttle suddenly while 88 backing aT RUIN Tan VANS A 0 a OPERATION Driving Safely Driving in Reverse 4 amp WARNING Failure to use caution when operating in reverse can result in serious injury or death Before shifting into reverse always check for obstacles or people behind the vehicle Drive slowly Avoid backing on inclines
33. S Rear Suspension Suspension Set Up 5 Remove the stand and have a rider sit comfortably on the seat with hands on the handlebars 6 Place the transmission in neutral and slowly roll the machine forward and rearward at least ten feet 3 m without lifting or pushing down on the suspension 7 Turn the handlebars fully to the left and right With the rider still on the vehicle repeat the measurement performed in step 4 9 Subtract the step 8 measurement from the step 4 measurement The difference should be between 4 and 4 25 inches 10 2 10 8 cm 10 If the number is less than 4 inches 10 2 cm decrease the rear spring preload on both shocks see page 161 and repeat all steps If the number is higher than 4 25 inches 10 8 cm increase spring preload and repeat all steps oo 159 ADJUSTMENTS Rear Suspension When the adjuster screw is turned counter clockwise until it stops the damping is in the softest position position 1 Turn the screw clockwise to increase damping NOTE Use a flat blade screwdriver to make damping adjustments Rear Shock Setting Compression Damping Position 1 Poston 4 Poston 7 160 ADJUSTMENTS Rear Suspension The rear suspension spring preload shock rebound damping and shock compression damping may be adjusted to suit different riding conditions and operator weight Spring Preload 1 Raise and safely support the rear of the ATV off the ground to allow the suspension t
34. Start the engine and allow it to warm up Turn engine off Unlatch and remove the seat Loosen the intake duct clamp at the carburetor and pull the duct off the carburetor Start the engine and spray Polaris fogging oil or a comparable product into the carburetor following the instructions on the fogging oil container Turn the engine off reassemble the intake duct to the carburetor secure the clamp and reinstall the seat 173 CLEANING AND STORAGE Storage Recommendations Inspect and Lubricate Inspect all cables and lubricate Follow lubrication guidelines in the Maintenance Section of the service or owner s manual to completely grease and lubricate the entire vehicle with Polaris Premium All Season Grease Engine Anti Freeze Test engine coolant strength and add or change coolant if necessary Replace coolant every two years Storage Area Covers Set the tire pressure and safely support the ATV with the tires 1 2 off the ground Be sure the storage area is well ventilated and cover the machine with a genuine Polaris ATV cover NOTE Do not use plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation 174 Transporting the ATV Follow these procedures when transporting the vehicle 1 Turn off the engine and remove the key to prevent loss during transporting 2 Turn the fuel valve off 3 Be sure the fuel cap oil cap and seat are installe
35. Storage Recommendations CAUTION Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur Never start the engine during the storage period Clean the Exterior Make any necessary repairs and clean the vehicle as recommended See page 167 Stabilize the Fuel Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer to the fuel tank following the instructions on the container for the recommended amount Fill the fuel tank with fuel Allow 15 20 minutes of operation for the stabilizer to disperse through the fuel in the tank and carburetor Turn the fuel valve off and drain the carburetor bowl NOTE Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust systems 171 CLEANING AND STORAGE Storage Recommendations Oil and Filter Warm the engine and change the oil and filter See page 105 Air Filter Air Box Inspect and clean or replace the pre cleaner and air filter Clean the air box and drain the sediment tube Breather Filter Inspect and clean or replace the breather filter inside the airbox Fluid Levels Inspect all fluid levels and change as outlined in the Maintenance Schedule beginning on page 92 Battery Refer to pages 135 137 for battery storage and battery charging procedures 172 CLEANING AND STORAGE Storage Recommendations Fog the Engine 1 2 3 4
36. ady for operation If you do not hear air the line has not bled and you ll need to repeat the priming procedure 110 MAINTENANCE AND LUBRICATION Engine Cooling System The engine coolant level is controlled or maintained by the recovery system The recovery system components are the recovery bottle radiator filler neck radiator pressure cap and connecting hose To ensure that the coolant maintains its ability to protect the engine we recommend that you completely drain the cooling system every two years and add a fresh mixture of antifreeze and water Polaris recommends the use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water See page 183 for the part numbers of Polaris products NOTE Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water NOTE Always follow the manufacturer s mixing recommendations for the freeze protection required in your area 111 MAINTENANCE AND LUBRICATION Engine Cooling System Coolant Level The recovery bottle 1 is located on the right side of the vehicle under the front fender The fluid level must be maintained between the FULL 2 and ADD 3 marks on the side panel when the fluid is cool As coolant operating temperature increases the expanding heated excess coolant is forced out of the radiator past the pressure cap and into the recovery bottle As engine
37. agm extends into the reservoir as fluid level drops If the fluid level is low and the diaphragm is not extended a leak is likely and the diaphragm should be replaced Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation Do not overfill See page 56 The front brakes are hydraulic disc brakes They re activated by squeezing the brake lever toward the handlebar The rear brake is a hydraulic disc brake activated by the foot brake pedal Both brakes are self adjusting but the following checks are recommended to keep the brake systems in good operating condition Check more often if brakes are used heavily under normal operation 4 amp WARNING An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill See page 56 146 ADJUSTMENTS Brakes 1 Always keep brake fluid at an adequate level See page 56 Check the brake system for fluid leaks Check the brakes for excessive travel or spongy feel Check the friction pads for wear damage and looseness Check the security and surface condition of the disc AnNRWN Inspect the rear brake disc spline and pad wear surface for excessive wear NOTE Pads should be changed when worn to 3 64 1 mm 3 64 1 mm 147 ADJUSTMENTS amp WARNING Severe injury or de
38. aintenance Chart beginning on page 92 Always change the oil filter whenever changing oil Perform a break in oil change after one hour of operation or after the first tank of fuel whichever comes first Change the oil more frequently on vehicles subjected to severe use 105 MAINTENANCE AND LUBRICATION Oil and Filter Change 1 Position the vehicle on a level surface 2 Clean the area around the oil tank 1 and crankcase 2 drain plugs with clean shop towels 3 Run the engine for two to three minutes until warm then stop the engine 4 Place a drain pan beneath the oil tank and remove the drain plug CAUTION Hot oil can cause serious burns to skin Do not allow hot oil to contact skin 5 Allow the oil to drain completely 6 Replace the sealing washer and reinstall the plug Torque to 14 ft lbs 19 Nm NOTE The sealing surfaces on drain plugs oil tank and crankcase should be clean and free of burrs nicks or scratches 106 MAINTENANCE AND LUBRICATION Oil and Filter Change 7 Place a drain pan beneath the crankcase and remove the drain plug 8 Allow the oil to drain completely 9 Replace the sealing washer and reinstall the plug Torque to 14 ft lbs 19 Nm 10 Place shop towels beneath the oil filter 11 Remove the three cover bolts and remove the cover 12 Pull out the oil filter NOTE A spring located behind the filter may pop out as the filter is removed The spring must be reinstalle
39. an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when possible SAFETY Operator Safety e Always follow proper procedures for e Always use proper procedures if you crossing the side of a hill Avoid hills with excessively slippery or loose sur faces Shift your weight to the uphill side of the ATV Never attempt to turn the ATV around on any hill until you ve mastered on level ground the turning technique outlined in this manual Avoid crossing the side of a steep hill when possible Always be careful of skidding or sliding On slippery surfaces like ice travel slow ly and use extra caution to reduce the chance of skidding or sliding out of con trol 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 proce dure described in this manual e Always check for obstacles before oper ating in a new area Never attempt to operate over large obstacles such as rocks or fallen trees Always follow proper procedures when operating over obstacles as described in this manual 21 SAFETY Operator Safety Avoid operating the ATV through deep or fast flowing water If it s unavoi
40. and the possibility of accident or severe injury See page 146 57 FEATURES AND CONTROLS Parking Brake 4 amp WARNING Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death Always check to be sure the parking brake is disengaged before operating Locking the Parking Brake 1 Place the transmission in first gear 2 Squeeze and release the brake lever two or three times then squeeze and hold 3 Push the parking brake lock down to engage the lock 1 Release the brake lever 4 To release the parking brake lock 2 squeeze and release the brake lever The lock will automatically disengage 58 FEATURES AND CONTROLS Parking Brake Important Safeguards The parking brake may relax if left on e Never depend on the parking brake alone for a long period of time Always block if the ATV is parked on a hill Always the wheels to prevent rolling block the wheels to prevent rolling e Always block the wheels on the downhill Place the transmission in first gear before side of the ATV if leaving it parked on a locking the parking brake hill Another option is to park the ATV in a sidehill position 59 FEATURES AND CONTROLS Fuel Tank The fuel tank filler cap is located directly below the handlebar Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Do not use E 85 fuel Fuel Filter The fuel valve has an internal f
41. ath can result from improper toe alignment and adjustment Do not attempt to adjust tie rod alignment All tie rod adjustments should be performed by an authorized Polaris dealer Toe Alignment Use the following procedure to check toe alignment The vehicle is designed for a neutral toe setting 1 Position the vehicle on a level surface 2 Place the handlebars in a straight ahead position Use tie straps to secure the handlebars to the rear grab bar so they can t move 3 Place stands 1 in front of the vehicle perpendicular to the rear tires See illustration 148 ADJUSTMENTS Toe Alignment 4 Tie an elastic string 2 around the stands making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in front of the vehicle 5 Measure the distance between the string in front of the rear tires A and in front of the front tires B If the two measurements are not equal adjust the string position until the measurements are equal 6 Measure the distance from the string to the rim at the front and rear of the front rim 3 The difference between these two measurements should be between 0 and 1 16 0 1 5 mm toe out NOTE If you discover improper alignment see your Polaris dealer for service ADJUSTMENTS Chain Tension CAUTION Never adjust or operate the vehicle with the rear drive chain too loose or too tight Severe damage to the
42. aust gases exit through the exhaust system Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design including factory set fuel delivery and ignition The engine and related components must be maintained at Polaris specifications to achieve optimal performance Engine idle speed is the only adjustment Polaris recommends that the operator perform Any other adjustments should be performed by an authorized Polaris dealer The emissions label is located on the recoil cover or stator housing 91 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Careful periodic maintenance will help keep your vehicle in the safest most reliable condition Inspection adjustment and lubrication of important components are explained in the following pages A tool kit is provided in the storage compartment under the seat Keep the tool kit with the vehicle at all times Maintenance intervals in the following charts 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 Record maintenance and service in the Maintenance Log beginning on page 195 92 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Severe Use Definition e Frequent immersion in mud water or sand e Racing or race style high RPM use Prolonged low speed heavy load opera tion e Extended idl
43. button for 10 second intervals for about one minute or until water vapor is no longer ejecting from the spark plug hole Check the oil level on the dipstick Ifthe level is higher than the pre ride inspection level water has entered the oil tank Do not start the engine Tow the ATV and see your dealer If the oil level is unchanged from the pre ride inspection level replace the spark plug start the engine and move the ATV promptly to a trailer or towing vehicle CAUTION If water isn t removed promptly from a submerged ATV rust will form in precision components gears bearings the cylinder and other areas and result in serious engine damage Always see your dealer promptly after an ATV has been submerged 133 MAINTENANCE AND LUBRICATION Battery The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Never pry the sealing strip off or add any other fluid to this battery Keep battery terminals and connections free of corrosion If cleaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the terminals with dielectric grease or petroleum jelly 4 amp WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing a battery always disconnect the negative black
44. charging terminals under the right front cab Removing the cab is not necessary NOTE The Polaris Battery Tender battery charger can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point 137 MAINTENANCE AND LUBRICATION Battery Charging Sealed Battery When using an automatic charger such as the Polaris Battery Tender refer to the manufacturer s instructions for recharging When using a constant current charger use the guidelines on the following page for recharging 4 amp WARNING An overheated battery could explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging 138 MAINTENANCE AND LUBRICATION Battery Charging Sealed Battery NOTE Always verify battery condition before and 1 2 hours after charging State of Voltage Charge Time Charge Using constant current charger standard amps specified on top of battery 100 12 8 13 0 volts None check at None required 3 mos from date of manufacture 75 100 12 5 12 8 volts May need slight charge 3 6 hours if no charge given check in 3 months 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with At least 20 hours desulfating charger
45. cline if possible If it s unavoidable follow these precautions 1 Turn the engine off 2 Place the transmission in first gear 3 Lock the parking brake 4 Always block the rear wheels on the downhill side See illustration 5 Turn the fuel valve off e a 84 OPERATION Driving Safely Driving Over Obstacles Be alert Look ahead and learn to read the terrain you re traveling on Be constantly alert for hazards such as logs rocks and low hanging branches 4 amp 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 85 OPERATION Driving Safely Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the level of the footpegs 1 Follow these procedures when operating through water 1 Determine water depths and current before crossing 2 Choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles if possible 4 After crossing dry the brakes by applying light pressure to the lever until braking action is normal After running the vehicle in water it s critical to have it serviced as outlined in the maintenance chart See page 92 The engine oil and all grease fittings need special attention 86 OPERATION Driving Safely Driving Through Water CAUTI
46. contact the Polaris War ranty Department at 1 763 417 8650 194 MAINTENANCE LOG Periodic Maintenance Record Use the following chart to record periodic maintenance Maintenance Servicing Servicing Interval Date Dealer Performed or Person 100 hrs MAINTENANCE LOG Maintenance Servicing Servicing Interval Date Dealer Performed or Person MAINTENANCE LOG Maintenance Servicing Servicing Interval Date Dealer Performed or Person INDEX A Age Restrictions 14 Air Filter Systems 114 115 B Battery lt 8 don seared tae AAS 134 Battery Charging Sealed Battery 137 139 Battery Installation 136 Battery Removal 135 Battery Storage 135 Boot Burping 145 Boot Inspection 144 Brake Fluid 56 57 Brake Levers 55 Brake Light Adjustment 120 Brakes iscsi sca a a tae sale 146 147 Break In Period 68 69 Cc Cab Removal Front 121 Cab Removal Rear 122 Camber and Caster 153 Carburetor Idle RPM 165 166 Chain Tension 150 151 198 Cc Choke aa n e ore ee 62 Clutch Lever 53 Clutch Lever Freeplay 163 Compression Damping 162 Coolant Level Radiator 113 Coolant Level Recovery Bottle 112 Cooling System 111 112 Crankcase Emission Control 91 D Driving Across Hills 80 Driving Downhill
47. coolant temperature decreases the contracting cooled coolant is drawn back up from the tank past the pressure cap and into the radiator NOTE Some coolant level drop on new machines is normal as the system Is purging itself of trapped air Observe coolant levels and maintain as s recommended by adding coolant to the recovery bottle am 112 MAINTENANCE AND LUBRICATION Engine Cooling System 4 amp 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 cap Radiator Coolant Level This procedure is required only if the cooling system has been drained for maintenance and or repair However if the recovery bottle has run dry inspect the level in the radiator and add coolant if necessary The radiator pressure cap is located on the left side of the vehicle 1 Remove the pressure cap 2 Using a funnel slowly add coolant as necessary through the radiator filler neck 3 Reinstall the pressure cap NOTE Use of anon standard pressure cap will not allow the recovery system to function properly Contact your dealer for the correct replacement part 113 MAINTENANCE AND LUBRICATION Air Filter Systems 1 Unlatch and remove the seat 2 Release the two airbox cover clips 1 and rotate the cover rearward to remove it 3 Remove the air filter retaining screw 2 5 mw 4 Loosen the filter clamp 3 5 Remo
48. ct periodically Oil Change 10H 100 160 Perform break in service after first hour of operation gt Oil Filter 10H 6M 100 160 Replace with oil change Battery 20H Monthly 200 320 Check terminals clean A Engine breather filter Monthly 200 320 Inspect clean as needed A General lubrication 50H 500 800 Lubricate all fittings pivots cables 97 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Interval whichever comes first Hours Calendar_ miles Km Carburetor float bow 500 800 Drain bow periodically and prior to storage em 50 Throttle Cable ETC 50 H 500 800 Inspect adjust replace if necessary Switch Choke enricher 50H 500 800 Inspect adjust lubricate replace if neces cable sary Drive chain s 500 800 Inspect daily adjust and lubricate if needed and filter in airbox Perform these procedures more often for vehicles subjected to severe use Emission Related Service Have an authorized Polaris dealer perform these services Polaris Premium All Season Grease omy 98 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Interval whichever comes first Hours Calendar _ Miles Km Upper steering 50H 3M 500 800 Inspect tighten fasteners grease after post A washing ATV or driving in water Front A Arms B 50H 3M 500 800 Inspect tighten fasteners grease also after washing ATV or driving in wat
49. d able travel slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward mo tion 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 wa ter If necessary apply them lightly sev eral times to allow friction to dry out the pads Always check for obstacles or people be hind the ATV before operating in re verse When it s safe to proceed in reverse move slowly and avoid turning at sharp angles Always use the size and type of tires spe cified for your ATV and always maintain proper tire pressure Never modify an ATV through improper installation or use of accessories Never exceed the stated load capacity for your ATV FOR MORE INFORMATION ABOUT ATV SAFETY call the Consumer Product Safety Commission at 1 800 638 2772 or visit www cpsc gov visit www atv safety org or call Polaris at 1 800 342 3764 22 SAFETY Operator Safety Equipment Modifications We are concerned for the safety of our customers and for the general public Therefore we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury The
50. d correctly 4 Always tie the frame of the ATV to the transporting unit securely as shown in the illustration using suitable straps or rope 5 Always place the transmission in first gear and lock the parking brake CLEANING AND STORAGE DYA Gj ie Zy j Sai gios we 0 0 ey Qe ge oq ve oe Naga Pan eg gt A an ae 175 TROUBLESHOOTING Contact your Polaris dealer for service if you re unable to identify solutions using the following charts Engine Doesn t Turn Over Possible Cause Solution Fuseable link See Polaris dealer for replacement Low battery voltage Recharge battery to 12 8 VDC Check all connections and tighten 176 TROUBLESHOOTING Engine Turns Over Fails to Start Possible Cause Solution Low battery voltage Recharge battery to 12 8 VDC Mechanical failure See your Polaris dealer Throttle ETC switch not opening Adjust throttle freeplay 177 No spark to spark plug Inspect plug s verify stop switch is on Overuse of choke Inspect clean and or replace spark plugs TROUBLESHOOTING Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Backfires Possible Cause Solution Weak fouled or defective spark plug Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs
51. d with the new filter 13 Using a clean dry cloth clean the filter sealing surfaces Step 12 107 MAINTENANCE AND LUBRICATION Oil and Filter Change 14 Replace the o ring in the cover 15 Lubricate the gasket on the new filter with a film of fresh engine oil 16 Reinstall the spring and install the new filter with the open end facing outward 17 Install the cover and torque the bolts to 72 78 in lbs 8 9 Nm NOTE The long bolt must be placed in the forward hole Step 14 108 MAINTENANCE AND LUBRICATION Oil and Filter Change 18 Remove the dipstick and fill the oil tank with the recommended oil 19 Place the transmission in neutral Lock the parking brake 20 Prime the oil pump using the procedure on page 110 Then stop the engine and inspect for leaks 21 Re check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick 22 Dispose of the used filter oil and shop towels properly 109 MAINTENANCE AND LUBRICATION Oil Pump Priming This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected 1 Clamp or pinch off the vent line 1 approximately 2 5 cm from the oil tank 2 Run the engine for 5 10 seconds at idle Stop the engine and 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 re
52. e e Short trip cold weather operation Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use genuine Polaris parts available from your Polaris dealer NOTE Service and adjustments are important for proper vehicle operation If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations 93 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule 4 amp WARNING Improperly performing the procedures marked with a m could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services Maintenance Chart Key p gt Perform these procedures more frequently for vehicles subjected to severe use E Enmission 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 Use Polaris Premium All Season Grease or grease conforming to NLGI No 2 such as Conoco Superlube M or Mobilegrease Special 94 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Interval whichever comes first Hoare Calendar wes m Brake systems fluid Pre Ride Inspect maintain fluid between fill lines a Pee we S S Wheels lug nuts PreRide _ Inspect tighten Fame fasteners Prena irere toen Air filter and Pr
53. e Avoid the use of harsh cleaners which can scratch the finish e Do not use a power washer to clean the vehicle 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 168 CLEANING AND STORAGE Washing the Vehicle If a high pressure water system is used for cleaning not recommended exercise extreme caution The water may damage components and could remove paint and decals Avoid directing the water stream at the following items e Wheel bearings e Cab and body panels e Transmission seals e Labels and decals e Brakes 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 169 CLEANING AND STORAGE 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 ve hicle 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 170 CLEANING AND STORAGE
54. e Ride Inspect clean replace as needed Pre cleaner Coan f Pene nspactlover add as neoded Fut _ Pene Fillo properes oil Tirole Premide heck operation SSSCSC S Pouch Prene Check operation and adusien fuss Prefide heck operation iS Engine stop wich PreRide Chest operation MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Interval whichever comes first Hours Calendar _ Miles Km Steering Pre Ride Check for free operation and loose compo nents Air box sediment Pre Ride Drain deposits when visible tubes Headlamp Pre Ride Check daily apply Polaris dielectric grease to connector when replaced emeen Pene o Check aay A arm ball joint Pre Ride Check freeplay daily have dealer replace if wheel moves excessively Rear shaft assembly Pre Ride Check pre ride for tears punctures leaking Post Ride Check post ride for bulging ballooning Replace if damaged Burp if bulging p Perform these procedures more often for vehicles subjected to severe use E Emission Related Service e Have an authorized Polaris dealer perform these services Polaris Premium All Season Grease MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Interval whichever comes first Hours Galendar_ miles Kr Air filter Weekly Inspect clean replace as needed main element m Brake pad wear Monthly 100 160 Inspe
55. e a possible fluid leak or low master cylinder fluid level which must be corrected before riding Contact your dealer for proper diagnosis and repairs 4 amp WARNING Operating the ATV with a spongy brake lever can result in loss of braking which could cause an accident Never operate the ATV with a spongy feeling brake lever 55 FEATURES AND CONTROLS Master Cylinder 1 The master cylinder 1 is on the right hand handlebar Check the brake fluid level before each ride The fluid level can be seen through thesight glass 2 on the side of the master cylinder Maintain the fluid level at or slightly above the mark 3 near the center of the sight glass Do not overfill 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 183 for the part numbers of Polaris products 56 FEATURES AND CONTROLS Master Cylinder 4 amp WARNING An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade
56. e basic warranty For questions call Polaris Customer Assistance United States 1 763 417 8650 Canada 1 204 925 7100 192 WARRANTY U S A EPA Emissions Limited Warranty This All Terrain Vehicle ATV or Off Road Utility Vehicle ORUV emissions limited warranty is in addition to the Polaris standard limited warranty for this vehicle Polaris warrants that this vehicle is 1 designed built and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and 2 free from defects in materials and workmanship that may keep it from meeting these requirements The emissions warranty period for this vehicle begins on the date the vehicle is delivered to the original retail pur chaser 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 recirculation 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 costs associated with recommended maintenance 193 WARRANTY U S A EPA Emissions Limited Warranty The exclusive remedy for breach of this limited warranty shall be at the exclusive option of Polaris
57. ee eee eee pre ea aaa eae pats 176 POLARIS PRODUGT S resies einen wala teew yan mhe a names 183 SPEGIFIGATIONS sda teas oe dana ta uae Fee eae aa eae eS 184 WARRANTY scan cow hse ede iw Sh bee Sawa eee heh heehee sae hwo 186 MAINTENANCE LOG fies ndash htt nee oe nek EE 195 TAIDI E Ue tine te tp aaa tite cad rte tap E na ig a we ea 198 KNOW YOUR VEHICLE As the operator of the vehicle you are responsible for your personal safety the safety of others and the protection of our environment Read and understand your owner s manual which includes valuable information about all aspects of your vehicle including safe operating procedures Vehicle Identification Numbers Record your ATV s identification numbers and key number in the spaces provided Remove the spare key 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 KNOW YOUR VEHICLE Vehicle Identification Numbers Vehicle Model Number Frame VIN 1 left side Engine Serial Number 2 right side Key Number 3 SAFETY Safety Decals and Locations Warning decals have been placed on the ATV for your protection Read and follow the instructions of the decals on the ATV carefully If any of the decals depicted in this manual differ from the decals on your ATV always read and follow the instr
58. ehicle was purchased you should take your ve hicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be autho rized to perform the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of the destination country before you move Vehicles importation rules vary considerably from country to country You may be required to present documentation of your move to Polaris Industries in order to continue your warranty coverage You may also be required to obtain documentation from Polaris Industries in order to register your ve hicle in your new country 191 WARRANTY Exported Vehicles How to Get Service If Purchased From A Private Party If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased all warranty coverage will be denied Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the proce dure set out above your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind Vehicles registered to Government officials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by th
59. ehicle will meet the efficiency requirements of 43 CFR 8340 1 c for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with Polaris recommendations 189 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WARRANTY OR SERVICE BUL LETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCATION This policy does not apply to vehicles that have received authorization for export from Polaris Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warran ty or service bulletin coverage if you have any questions This policy does not apply to vehicles registered to government officials or military personnel on assignment out side the country of the selling dealer s authorized location This policy does not apply to Safety Recalls 190 WARRANTY Exported Vehicles How to Get Service In the Country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer If you move or are traveling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your v
60. ent of throttle cable freeplay can result in loss of control which could result in serious injury or death Polaris recommends that this procedure be performed by a Polaris dealer to ensure that it s done correctly Mechanically knowledgeable persons who perform this procedure must follow the adjustment procedures exactly Throttle cable freeplay is adjusted at the handlebar 1 Slide the boots 1 off the inline cable 1 2 3 1 adjuster sleeve 2 and loosen the adjuster A locknut 3 ze 2 Turn the adjuster until 1 16 to 1 8 1 5 3 mm freeplay is achieved at the thumb lever NOTE While adjusting freeplay be sure to flip the throttle lever back and forth 3 Tighten the locknut and slide the boots over the cable adjuster until they touch at the midpoint of the adjuster 164 ADJUSTMENTS Carburetor Idle RPM If the engine idle speed is not satisfactory and all other conditions are favorable the carburetor can be adjusted 1 Warm up the engine by running the vehicle for five minutes or until operating temperature is reached 2 Apply the parking brake and place the transmission in neutral 3 Adjust the carburetor idle screw 1 either in or out until the desired idle RPM is reached Turning the screw in clockwise will raise RPM Turning the screw out counterclockwise will lower RPM 165 ADJUSTMENTS Carburetor Idle RPM Carburetor re jetting can be performed to compensate for
61. er Rear Control Arm 50H 3M 500 800 Inspect tighten fasteners grease also Bushings C after washing ATV or driving in water Rear Control Arm 12M 1000 1600 Disassemble clean inspect bearings and Needle Bearings E seals grease reassemble 7 BO C D E A Y g 99 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Interval whichever comes first Hours Calendar_ Miles Km Coolant strength 50 H 500 800 Inspect strength seasonally pressure test system annually Coolant system 100 H 12M 1000 1600 Pressure test system annually pressure test E Spark plug 100 H 1000 1600 Inspect replace as needed Fuel system 100 H 12M 1000 1600 Check for leaks at tank cap lines fuel valve pump and carburetor replace lines every two years z Ignition Timing A eS ae Inspect adjust as needed Perform these procedures more often for vehicles subjected to severe use Emission Related Service Have an authorized Polaris dealer perform these services Polaris Premium All Season Grease omy 100 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Interval whichever comes first Hours Calendar_ Miles Km Radiator 100 H 12M 1000 1600 Inspect clean external surface change coolant every 2 years gt Coating system hoses 100 1000 1600 Engine mounts 100 7000 7600 m Brake fluid 200 H 2000 3200 Change every two years Sparcarrestor 300H 3
62. etween 3 75 and 4 inches 9 5 10 2 cm 10 If the number is less than 3 75 inches 9 5 cm decrease the front spring preload see page 157 and repeat all steps If the number is higher than 4 inches 10 2 cm increase spring preload and repeat all steps 155 ADJUSTMENTS Front Suspension Spring Preload The front suspension preload may be adjusted to suit different riding conditions and operator weight 4 amp WARNING Uneven adjustment may cause poor handling of the ATV which could result in an accident and serious injury or death Always adjust both the left and right spring preloads equally or have your Polaris dealer perform the adjustments 156 Front Suspension Spring Preload 1 Raise and safely support the front of the ATV off the ground to allow the suspension to fully extend Turn the adjusting ring 1 clockwise to increase preload A Turn the ring counter clockwise to decrease preload B ADJUSTMENTS AG DB A A a 157 ADJUSTMENTS Rear Suspension Suspension Set Up 1 Position the vehicle on a level surface 2 Stop the engine 3 Elevate the rear of the vehicle by placing a suitable stand under the frame NOTE The tires should be barely touching the ground and the suspension should be at full rebound 4 Measure the distance from the ground to the bottom of the rear lower control arm pivot bolt Note this measurement for later use 158 ADJUSTMENT
63. fort and protection SAFETY Operator Safety 4 amp WARNING Failure to follow the warnings contained in this manual can result in serious injury or death A Polaris ATV is not a toy and can be hazardous to operate This vehicle handles differently than other vehicles such as motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions Read and understand your owner s manual and all warnings before operating a Polaris ATV Operator Restrictions Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age This category S Sport ATV is a high performance vehicle intended for off road use only for sport type recreation and for competitive use by operators with advanced skills and substantial experience 14 Operator Safety Safety Training ATV safety training is a top priority for Polaris When you purchased your new ATV your dealer instructed you on the authorized ATV RiderCourse available to you and your eligible family members This training is included in the purchase price of your ATV Polaris strongly encourages you and your eligible family members who will be riding the ATV to take the ATV RiderCourseS You were also provided with printed materials that explain safe operating procedures You should review this information on a regular
64. from the fuel valve fitting on the gas tank 4 Remove the vent hose 2 from the steering post taking note of the hose routing for reinstallation 126 MAINTENANCE AND LUBRICATION Spark Plugs Spark Plug Removal and Replacement 5 Remove the tank mounting bolt 3 at the rear of the gas tank 6 Move the tank rearward and upward over the engine Slowly remove the tank and be careful not to catch any hoses wires or other components Place the tank on a stable surface or work bench Be sure to protect the valve from contamination or damage 7 Using the forked end of the spark plug wrench handle remove the spark plug boot IMPORTANT Do not pull on the wire to remove the boot Doing so may cause a wire disconnection inside the boot 8 Using the spark plug wrench and handle rotate counterclockwise to remove the spark plug 9 Reverse all steps to install the spark plug and reassemble the body Torque the spark plug to 14 ft lbs 19 Nm Be sure to reroute the vent hose down the steering post Torque the tank mounting bolt to 9 ft Ibs 12 Nm 127 MAINTENANCE AND LUBRICATION Spark Arrestor Clean Out 4 amp WARNING 128 Do not perform clean out immediately after the engine has been run as the exhaust system becomes very hot Serious burns could result from contact with the exhaust components Wear eye protection and gloves Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas
65. h of travel r 7 ae wt Release the parking brake nh Adelie Slowly depress the throttle with your right As gt thumb while slowly releasing the clutch phe SEIN lever to begin driving Drive slowly Practice maneuvering and using the throttle clutch and brakes on level surfaces OPERATION Driving Safely Making Turns Your ATV is equipped with a solid rear axle which drives both rear wheels equally at all times The wheel on the outside of the turn travels a greater distance than the inside wheel when turning lt and the inside tire slips traction slightly To turn steer in eS the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footpeg This technique alters the balance of NSS 6 oe ors traction between the rear wheels allowing the turn to Pen re as TNS be made smoothly The same leaning technique a 5 ADA o should be used for turning in reverse NOTE Practice making turns at slow speeds Pe a before attempting to turn at faster speeds amp WARNING Turning at sharp angles or at excessive speeds can result in vehicle overturn and lead to serious injury or death Avoid turning at sharp angles Never turn at high speeds 77 OPERATION Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel or during freezing weather follow these precautions 1 Slow down when entering slippe
66. hile starting the engine NOTE Excessive engagement may result in starter damage 7 Ifthe engine does not start wait five seconds after releasing the start button then activate the starter for another five seconds Repeat until the engine starts 8 Ifthe engine slows or stops position the choke knob half way in to allow proper engine warm up 9 Vary the engine RPM slightly with the throttle to aid in warm up When the engine idles smoothly push the choke completely in 74 OPERATION Starting a Warm Engine Follow the procedure for starting a cold engine but do not use the choke If the engine has cooled to a point where it does not readily start intermittent use of the choke pulled half way out may be necessary If you believe the engine is over choked when warm push the choke lever completely in and depress the throttle lever fully while cranking to aid in starting Release the throttle lever immediately after the engine starts If the engine does not start review the engine troubleshooting information beginning on page 176 If all conditions are favorable and the engine still does not start see your Polaris dealer for service 75 OPERATION Driving Safely Driving Procedures 1 2 3 76 Sit upright with both feet on the footpegs and both hands on the handlebars Start the engine and allow it to warm up then shift the transmission into gear See page 64 Check your surroundings and determine your pat
67. icals known to cause cancer birth defects or other reproductive harm A card containing important ATV safety information should be attached to the owner s manual on the next page If you cannot locate this card or if it has been removed please call 1 800 342 3764 for assistance GD POLARIS e Way Out POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries 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 discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited Printed in U S A 2007 Outlaw Owner s Manual P N 9920783 2 WELCOME Thank you for purchasing a Polaris vehicle and welcome to our world wide family of Polaris owners We proudly produce an exciting line of utility and recreational products e Snowmobiles e All terrain vehicles ATVs e RANGER utility vehicles e Victory motorcycles WELCOME We believe Polaris sets a standard of excellence for all utility and recreational vehic
68. in water deeper than the footpeg level it s critical to dry it promptly and properly before starting the engine CAUTION Do not start the engine after an ATV has been in water that exceeds the recommended depth Serious engine damage WILL occur Tow or trailer the ATV to your dealer for service In an emergency perform the temporary drying out procedure outlined below which will allow short term operation only to drive the ATV to a trailer or towing vehicle Do not perform the following procedures if you don t feel completely capable or if you suspect that water has entered the fuel tank likely if the water was deep or if the ATV overturned Tow or trailer the ATV to your dealer for immediate service 131 MAINTENANCE AND LUBRICATION Vehicle Immersion 1 Turn the fuel valve off 2 Drain water from the air box and clean the air filter if equipped See page 114 3 Drain the fuel water from the carburetor for about 10 seconds 4 Remove the spark plug See page 125 4 amp WARNING Fluids will be ejected through the spark plug hole and may cause serious injury to face or other body parts Stand clear of the spark plug while performing the following steps 5 Intermittently and briefly touch the starter button in half second intervals to SLOWLY rotate the engine three or four times Water will eject from the spark plug hole 132 MAINTENANCE AND LUBRICATION Vehicle Immersion 6 he Press and hold the starter
69. ion is shifted out of reverse gear 65 FEATURES AND CONTROLS Manual Shift Deceleration To slow or stop the ATV release the throttle lever and apply the brakes smoothly and evenly As the vehicle slows and engine RPM decreases disengage the clutch and shift to a lower gear NOTE Be sure the engine RPM has sufficiently decreased before shifting to a lower gear 4 amp WARNING Improper use of the brakes or shifting when the engine RPM is too high can cause the tires to lose traction or stop rotating which could lead to loss of control accident and injury It could also cause engine or drive train damage Make sure the engine RPM has sufficiently decreased before shifting to a lower gear 66 Fuel Safety 4 amp WARNING OPERATION Gasoline is highly flammable and explosive under certain conditions e Always exercise extreme caution whenev er handling gasoline e Always refuel with the engine stopped and outdoors or in a well ventilated area e Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored e Do not overfill the tank Do not fill the tank neck e If gasoline spills on your skin or clothing immediately wash it off with soap and wa ter and change clothing e Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of con sciousness or death in a short time e Turn the fuel valve
70. it counterclockwise 1 to remove the bulb On the right headlamp turn the bulb housing clockwise 2 to remove the bulb 3 Apply dielectric grease to the socket and install the new bulb Rotate firmly NOTE The bulb must be positioned so the harness installs into the lamp at outer side 4 Reinstall the connector to the back of the headlight 117 MAINTENANCE AND LUBRICATION Lights Headlight Assembly Replacement Remove the wire harness connector from the headlights Remove the front cab see page 121 Remove the small adjuster bracket 1 Install it on the new lamp Remove the large pivot bracket 2 and remove the headlamp RS Goh Install the new headlamp by inserting the outboard pivot pin in the hole of the mounting tab on the cab 6 Install the adjuster bracket onto the inboard pivot pin of the headlamp Adjust for approximately 1 16 clearance between the bracket and the edge of the headlight Tighten the mounting screws IMPORTANT Be sure the bracket is 90 degrees to the pivot pin so the lamp can move freely 7 Install the adjusting screw leaving it loose so the headlight can be adjusted Reinstall the front cab Connect the wire harness to the headlamp 9 Adjust the lamps as needed then tighten the adjuster screw See page 119 oo 118 MAINTENANCE AND LUBRICATION Lights Headlight Adjustment 1 2 Position the ATV on a level surface with the headlight approximately 25 ft
71. itions Do not operate at sustained idle Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 70 During the break in period change both the oil and the filter after one hour of operation or after using the first tank of fuel 69 OPERATION Pre Ride Inspection 4 amp WARNING If a proper inspection is not done before each use severe injury or death could result Always inspect the vehicle before each use to ensure it s in proper operating condition tem CRemarce CCS Page Suspension Fontandrear_ Inspect bricatefnecessary Seeng Ensweteeoperaton f o 70 OPERATION Pre Ride Inspection Pre Ride Checklist Frame nuts bots fasteners Inspect ensuretghiness f Cooiant hoses applicable nspectiores f Cid indicator igts Tewches Ensure operation f a Engine stop switch Ensure proper operation _ d the socket when the lamp is replaced Wear helmet goggles protective clothing A arm ball joints Check freeplay If the tire moves excessively do not operate See your Polaris dealer 2 Rear shaft assembly Check boots for tears punctures and grease leaks OPERATION Starting a Cold Engine The engine can be started when the transmission is in neutral or while in gear if the clutch is disengaged 4 amp WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness
72. l accident and or injury HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement If it s unavoidable travel slowly and avoid sudden turns or stops SAFETY Operator Safety 4 amp WARNING POTENTIAL HAZARD Operating this ATV on public streets roads or highways WHAT CAN HAPPEN The ATV could collide with another vehicle HOW TO AVOID THE HAZARD Never operate the ATV on any public street road or highway including dirt and gravel roads In many states it s illegal to operate ATVs on public streets roads and highways 29 SAFETY Operator Safety 4 amp WARNING 30 POTENTIAL HAZARD Operating this ATV without wearing an approved helmet eye protection and protective clothing WHAT CAN HAPPEN Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident Operating without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants SAFETY Operator Safety 4 amp WARNING POTENTIAL HAZARD Operating the ATV after consuming alcohol or drugs WHAT CAN HAPPEN Consumption of alcohol and or drugs could seriously affect operator judgment Reaction
73. l never back it down the hill One maneuver that can be used when it s necessary to turn around while climbing a hill is the K turn 1 Keep your body weight uphill 2 Pull in the clutch lever and apply the front and rear brakes 3 When completely stopped shut off the engine Leaving the transmission in gear release the clutch lever and lock the parking brake 4 Dismount on the uphill side of the vehicle or on the left side if the vehicle is pointing straight uphill 82 OPERATION Driving Safely Turning Around on a Hill 5 Staying uphill of the ATV turn the handlebars full left Reach across the handlebar and apply the front brakes to unlock the parking brake 6 With the front brakes applied pull in the clutch lever Use the brakes to slowly allow the vehicle to roll around to your right until it s pointing across the hill or slightly downward 7 With the front brakes still applied release the clutch lever and lock the parking brake Remount from the uphill side keeping body weight uphill 8 Pull in the clutch lever shift into neutral and restart the engine 9 Release the parking brake and slowly release the clutch lever allowing the ATV to proceed slowly Stay in first gear using the brakes for additional speed control if necessary until more level ground is reached Do not apply the brakes abruptly when driving downhill 83 OPERATION Driving Safely Parking on an Incline Avoid parking on an in
74. les manufactured in the world today Many years of experience have gone into the engineering design and development of your Polaris vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your service needs during and after the warranty period We also take great pride in our Parts Apparel and Accessories PAA products available through our online store at www purepolaris com Have your accessories and clothing delivered right to your door TABLE OF CONTENTS KNOW YOUR VEHICLE 23 cute tnetambaheedhu ney came a aa we 6 SAFE TY udalsha catia cee ee aaa Saree E EEE aa 8 FEATURES AND CONTROLS 0 cece eee eee 48 OPERATION A yrr ona se at pias Se te ai ee as sae we eee he ae 67 EMISSION CONTROL SYSTEMS 00 c cece eee 90 MAINTENANCE AND LUBRICATION 0 000 e eee eee ees 92 ADJUSTMENTS irpan ase EEE awh aie a Se OAc pale ick 146 CLEANING AND STORAGE 0 0 e eee eee eee 167 TROUBLESHOOTING esaa et pis oe P
75. lways maintain proper tire pressure as described in the owner s manual and on safety decals WARNING POTENTIAL HAZARD Overloading the ATV or carrying towing cargo WHAT CAN HAPPEN Overloading or carrying towing cargo can cause changes in vehicle handling which could lead to loss of control or an accident HOW TO AVOID THE HAZARD Never haul cargo or tow a load with this ATV Never exceed the stated load capacity for this ATV SAFETY Operator Safety 4 amp 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 45 SAFETY Operator Safety 4 amp WARNING 46 POTENTIAL HAZARD Operating on frozen bodies of water WHAT CAN HAPPEN Severe injury or death can result if the ATV and or the operator fall through the ice HOW TO AVOID THE HAZARD Never operate the ATV on a frozen body of water WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN The ATV could collide with
76. n result if you do not follow these instructions and procedures which are outlined in further detail within your owner s manual e Read this manual and all labels carefully e Never allow anyone under 16 years of and follow the operating procedures de age to operate this ATV scribed e Never permit a guest to operate the ATV e Never operate an ATV without proper unless the guest has read this manual and instruction Take a training course Pur all product labels and has completed a chasers of a new Polaris ATV and their certified safety training course eligible family members are entitled to Always avoid operating an ATV on take the ATV RiderCourseS Contact paved surfaces including sidewalks ATV Enrollment Express at 800 driveways parking lots and streets 887 2887 or visit www atvsafety org for information on enrollment in the ATV RiderCourse 18 Operator Safety Never operate an ATV on a public street road or highway including a dirt or grav el 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 Trav el at speeds appropriate for the terrain visibility and operating conditions and your experience SAFETY Never attempt jumps or other stunts Always inspect yo
77. ng without releasing the throttle and disengaging the clutch could cause loss of control or vehicle overturn Always release the throttle and fully squeeze the clutch lever while shifting gears FEATURES AND CONTROLS Manual Shift Shifting Gears NOTE Always allow a cold engine to warm up before shifting gears 1 When starting from a stopped position place the transmission in neutral 2 Squeeze and hold the brake lever NOTE Do not squeeze the throttle lever Squeeze the clutch lever to disengage the clutch Depress the gear shift pedal one full stroke to shift into first gear Release the brake lever Gradually squeeze the throttle lever while slowly releasing the clutch lever As engine speed RPM increases in first gear simultaneously release the throttle disengage the clutch and shift to second gear by raising the gear shift pedal one full stroke Repeat this procedure to progressively upshift to additional gears 8 Use the same procedure to downshift SION Re 64 FEATURES AND CONTROLS Manual Shift Reverse Lock Out Switch The reverse lock out switch 1 2 cal prevents the operator from T shifting into reverse unintentionally fr 1 Place the transmission in first gear See page 63 1 2 Push the lock out lever forward toward the handlebar to unlock the transmission 3 Shift down into reverse gear NOTE The lock will automatically re engage when the transmiss
78. o fully extend 2 Turn the adjusting ring 1 clockwise A to increase preload Turn the ring counter clockwise B to decrease preload 161 Rear Suspension Compression Damping The compression damping clickers 1 are located on the bottom of the shocks on the lower clevis Use a screwdriver to make adjustments To set the shock at the softest setting position 1 turn the screw counter clockwise until it stops From this position turn the screw clockwise to increase compression damping Setting Compression Damping Position 1 Position 7 162 ADJUSTMENTS Clutch Lever Freeplay 1 Measure clutch lever freeplay between the perch and the lever A This distance should be 1 8 3 16 3 4 7 mm If adjustment is required slide the clutch perch pivot boot down the clutch cable to access the clutch adjustment screw B and lock ring C Loosen the lock ring and turn the screw in clockwise to increase lever travel Turn the screw out counterclockwise to decrease lever travel Tighten the lock ring Squeeze the lever fully and release Slightly squeeze the lever again until a slight resistance is felt Measure the freeplay again If necessary repeat the adjustment procedure until proper freeplay is attained Replace the clutch perch pivot boot over the screw and lock ring 163 ADJUSTMENTS Throttle Cable Freeplay 4 amp WARNING Improper adjustm
79. oling efficiency 182 POLARIS PRODUCTS Part Description Part Description E Ename Lubrioam coom 2874414 Performance Synthetic 4 Stroke PS 4 OW at _ 2871323 2874415 PS 4 Oil gal 2871534 Grease Specialized Lubricants SCSCSC SC C 2871312 Grease Gun Kit Premium Al Season oz Additives Miscellaneous 2871322 Premium All Season Grease 3 oz cartridge 2871326 Carbon Clean Plus 12 0z 2871423 Premium All Season Grease 14 oz cartridge 2870652 2671460 Starter Drive Grease oz 2872189 DOT 4 Brake Fuuid 12 02 E E E E 2872893 Engine Degreaser 12 oz 287132 2872073 2872348 135004 183 SPECIFICATIONS OUTLAW a a for oo 184 SPECIFICATIONS OUTLAW Driving System Type Rear Two Wheel Drive Tire Size Pressure Front 21 x 7R10 5 psi a Jetting Chart Altitude AMBIENT Below 40 F 40 F and above 5 C and above TEMPERATURE Below 5 C Meters 0 1800 Feet 0 6000 1800 3700 137 5 6000 12000 185 WARRANTY LIMITED WARRANTY Polaris Sales Inc 2100 Highway 55 Medina MN 55340 gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle ATV against defects in material or workmanship Polaris also gives a one year limited warranty on the final drive chain for failure due to defects This warranty covers the parts and labor charges for repair or replacement of defective parts which a
80. peed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill SAFETY Operator Safety 4 amp WARNING POTENTIAL HAZARD Traveling downhill improperly WHAT CAN HAPPEN Improperly descending a hill could cause loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner s manual NOTE A special technique is required when braking while traveling downhill See page 81 Always check the terrain carefully before descending a hill Shift your weight backward Never travel down a hill at high speed Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when possible 39 SAFETY Operator Safety 4 amp WARNING POTENTIAL HAZARD Improperly crossing hills and turning on hills WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of control or overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 82 Use extra caution when turning on any hill Avoid crossing the side of a steep hill When crossing the side of a hill Always follow proper procedures as described in the owner s manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the
81. re covered by this warranty This warranty begins on the date of purchase This warranty is transferrable to another consumer during the warranty period through a Polaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REG ISTERED WITH POLARIS Initial dealer preparation and set up of your ATV is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage 186 WARRANTY WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any ATV that has been altered structurally modified neglected improperly maintained used for racing or used for purposes other than for which it was manufactured or for an
82. ry areas 2 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids ae ee UNY 3 Correct a skid by turning the handlebars in the ie A 7 S TRE a direction of the skid and shifting your body weight forward SS W 4 amp WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control accident and serious injury or death Never apply the brakes during a skid Do not operate on excessively slippery surfaces Always reduce speed and use additional caution especially when downshifting 78 OPERATION Driving Safely Driving Uphill Whenever traveling uphill follow these precautions 1 Always travel straight uphill 2 Avoid steep hills 25 maximum 3 Keep both feet on the footpegs and transfer your weight forward 4 Proceed at a steady rate of speed and throttle opening 5 Be alert and prepared to take emergency action This may include quick dismounting of the vehicle 4 amp 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 Use extreme caution when operating on hills and follow all procedures outlined in the owner s manual 79 OPERATION Driving Safely Driving Across Hills 4 amp WARNING Improperly crossing hills or turning on hills can re
83. serious burns Wear protective gloves when removing a spark plug for inspection Allow components to cool before continuing 123 MAINTENANCE AND LUBRICATION Spark Plugs 1 Normal The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service NOTE The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetion adjustments 2 Wet Fouled The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended oil improper use of the choke or incorrect carburetion adjustments 124 MAINTENANCE AND LUBRICATION Spark Plugs Spark Plug Removal and Replacement 1 Remove the side panels and front cab see page 121 2 Turn the fuel valve off 4 amp WARNING A hot ember on the ATV could cause fuel to ignite Allow all components to cool sufficiently before accessing the spark plug Always exercise extreme caution when handling fuel systems and gasoline Always heed the fuel warnings on page 67 125 MAINTENANCE AND LUBRICATION Spark Plugs Spark Plug Removal and Replacement 3 Move the fuel valve hose clamp 1 forward and gently remove the hose
84. sult in loss of control or vehicle overturn resulting in severe injury or death Avoid crossing the side of a hill when possible Follow proper procedures as outlined in the owner s manual If you enter into a situation where sidehilling is unavoidable 1 Slow down 2 Lean into the hill transferring your upper body weight toward the hill while keeping your feet on the footpegs 3 Steer slightly into the hill to maintain vehicle direction NOTE Ifthe vehicle begins to tip quickly turn the front wheels downhill if possible or dismount on the uphill side immediately 80 OPERATION Driving Safely Driving Downhill Whenever descending a hill follow these precautions 1 Proceed directly downhill 2 Transfer your weight to the rear of the vehicle 3 Slow down 4 Shift to the lowest gear possible while maintaining a safe speed 5 Apply the foot brake slightly to aid in slowing 4 amp WARNING Excessive speed can cause loss of control and lead to serious injury or death Always operate slowly when traveling downhill 81 OPERATION Driving Safely Turning Around on a Hill 4 amp WARNING Improper hill climbing procedures could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 25 maximum Use extreme caution when operating on hills and follow proper operating procedures outlined in the owner s manual If the vehicle stalls while climbing a hil
85. time may be slower and operator balance and perception could be affected Consuming alcohol and or drugs before or while operating an ATV could result in an accident causing severe injury or death HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while operating an ATV 4 amp WARNING POTENTIAL HAZARD Operating the ATV at excessive speeds WHAT CAN HAPPEN Excessive speed increases the operator s chance of losing control of the ATV which can result in an accident causing severe injury or death HOW TO AVOID THE HAZARD Always operate the ATV at a speed that s proper for the terrain visibility and operating conditions and your experience 31 SAFETY Operator Safety 4 amp 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 32 SAFETY Operator Safety 4 amp WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the owner s manual 33 SAFETY Operator Safet
86. transmission and drive components can result Check the amount of chain slack by moving the vehicle slightly forward to remove slack at the top side of the chain At the center point of the top side of the chain there should be 1 4 3 8 6 9 mm deflection i ZIM Use the procedure on the following page if the chain needs adjustment NOTE The chain has a press on master link A chain tool must be used if it s necessary to remove the chain for service 150 ADJUSTMENTS Chain Tension 1 Loosen the upper and lower pivot mounting bolts 1 Thread the chain adjusting bolt 2 inward or outward to adjust chain slack to the proper dimension Tighten the pivot mounting bolts to 30 ft Ibs 40 Nm Torque the chain adjusting bolt to 17 ft Ibs 23 Nm 151 ADJUSTMENTS Handlebars If desired the handlebars can be adjusted for rider preference 4 amp WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block bolts can cause limited steering or loosening of the handlebars which could result in loss of control and serious injury or death Follow the adjustment procedures exactly or see your Polaris dealer for service 1 Loosen the four handlebar bolts 1 Adjust the handlebar to the desired height Be sure the handlebars do not contact the gas tank or any other part of the machine when turned ae ge t fully to the left or right 3 Torque the front two bolts to 1
87. uctions of the decals on the ATV If any decal becomes illegible or comes off contact your Polaris dealer to purchase a replacement Replacement safety decals are provided by Polaris at no charge The part number is printed on the decal Safety Decals and Locations General Warning 1 WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate e without proper training or instruction e at speeds too fast for your skills or the condi tions e on public roads a collision can occur with another vehicle e with a passenger passengers affect balance and steering and increase risk of losing control SAFETY ALWAYS e use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns e avoid paved surfaces pavement may seri ously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS IF OWNER S MANUAL IS MISSING CONTACT A POLARIS DEALER FOR A REPLACEMENT SAFETY Safety Decals and Locations Age 16 Warning 2 WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death NEVER operate this ATV if you are under age 16 Sport ATV Warning 3 WARNING This ATV may exceed the performance of other ATVs you may have ridden
88. uel filter Do not attempt to clean the fuel filter See your Polaris dealer for service if you suspect the fuel filter is plugged 60 FEATURES AND CONTROLS Fuel Valve The fuel valve 1 is located on the left side of the ATV It has three positions OFF For vehicle storage and when transporting ON For normal operation RES For reserve supply if main supply is exhausted NOTE There s about a 5 to 8 mile 8 to 13 km range on reserve gas Always refill the gas tank as soon as possible after using the main supply Always return the valve to the ON position after refueling 61 FEATURES AND CONTROLS Choke The choke assists in starting a cold engine The choke knob 1 is located on the left side of the vehicle Refer to the engine starting procedure on page 72 for correct choke and throttle settings during starting 62 FEATURES AND CONTROLS Manual Shift Shift Pedal The gear shift pedal is located in front of the left hand footpeg One full stroke of the pedal shifts the transmission to the next gear in the shifting sequence The pedal automatically returns to a horizontal position when released To upshift to a higher gear place the toe of your boot under the gear shift pedal and raise the pedal one full stroke To downshift place your foot on the gear shift pedal and depress the pedal one full stroke See page 64 NOTE To shift into reverse see page 65 4 amp WARNING Shifti
89. ur ATV before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and sched ules outlined in your owner s manual Always keep both hands on the handle bars and both feet on the footpegs of the ATV during operation Always travel slowly and use extra cau tion when operating on unfamiliar ter rain Be alert to changing terrain conditions SAFETY Operator Safety Never operate on excessively rough slip pery or loose terrain Always 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 Always have the ATV inspected by an authorized Polaris dealer if it s been in volved in an accident Never operate on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills 20 e Always follow proper procedures for climbing hills Check the terrain careful ly before ascending a hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes Never go over the top of a hill at high speed Always follow proper procedures for go ing downhill and for braking on hills Check the terrain carefully before you start down a hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at
90. ve the main air filter 4 6 Remove the pre filter 5 from the main filter element 7 Remove the breather filter 6 8 Wash the pre filter and breather filter in soapy water then rinse and let dry 114 MAINTENANCE AND LUBRICATION Air Filter Systems 9 Wash the main filter element 4 without removing it from the internal filter cage Rinse and let dry 10 Apply a commercially available foam filter lubricant to the foam filter 11 Reinstall all components 12 Check the hoses for cracks deterioration abrasion or leaks Replace as needed CAUTION Operation of your vehicle without a breather filter can cause engine damage Always reinstall the breather filter after removing for service 115 MAINTENANCE AND LUBRICATION Lights When servicing a halogen lamp don t touch the lamp with bare fingers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp 4 amp WARNING Poor lighting while driving can result in severe injury or death Headlight and taillight lenses become dirty during normal operation Wash the headlights frequently to maintain lighting quality Hot components can cause serious burns to skin Do not service the headlamps until they ve cooled sufficiently 116 MAINTENANCE AND LUBRICATION Lights Headlight Lamp Replacement 1 Remove the wire harness connector from the back of the headlight 2 On the left headlamp grasp the bulb housing and turn
91. y 4 amp WARNING 34 POTENTIAL HAZARD Removing hands from the handlebars or feet from the footpegs during operation WHAT CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV If the operator s foot is not firmly planted on the footpeg it could come into contact with the rear wheels and lead to accident or injury HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footpegs of the ATV during operation SAFETY Operator Safety 4 amp WARNING POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions 35 SAFETY Operator Safety 4 amp WARNING 36 POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough slippery or loose terrain WHAT CAN HAPPEN Operating on excessively rough slippery or loose terrain could cause loss of traction or loss of control which could result in an accident or overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you ve learned and practiced the skills necessary to control
92. y damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the ATV due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the ATV The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replace ment of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRAN TY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law 187 WARRANTY WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN

Polaris 9919412 Offroad Vehicle User Manual

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