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Polaris 800 EFI Touring Quadricycle Offroad Vehicle User Manual

1. fuge QNA NE Adjuster 86 MAINTENANCE Side Panel Removal l Footwell Removal l 2 3 Remove the seat Grasp the rear of the side panel near the rear cab With a firm motion pull the panel outward to disengage the side panel from the grommet Pull the panel downward and rearward to remove it When reinstalling side panels align the fasteners and press firmly to secure them Remove the six screws on the bottom of the footwell Use a flat screwdriver or sidecutters to remove the plastic rivets securing the footwell to the fenders Remove the footwell Hivets 87 MAINTENANCE Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar 1 Locate the throttle cable adjuster at the handlebar A ___ fH HEU Fi S DOES 2 Squeeze the end of the rub ber boot and slide it far enough to expose the end of the inline cable adjuster 3 Loosen the adjuster lock nut Lock Nut Adjuster 4 Rotate the boot to turn the adjuster until 1 6 3 2 mm of freeplay 1s achieved at the thumb lever NOTE Move the throttle lever back and forth while adjusting 5 Tighten the lock nut 6 Squeeze the end of the rubber boot and slide it over the cable adjuster to its original position NOTE Engine RPM should not increase when steering is turned full left or right Readjust cable freeplay if this occurs 88 MAINTENANCE Tires Refer t
2. Do not depend on eyeglasses or sunglasses for eye protection When ever riding a Polaris vehicle always wear shatterproof goggles or use a shatterproof helmet face shield Polaris recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Gloves Off road style gloves with knuckle pads are the best for comfort and protection Boots The best footwear is a pair of sturdy over the calf boots with low heels Clothing Always wear long sleeves and long pants to protect arms and legs Riding pants with kneepads and a jersey with shoulder pads provide the best protection 19 FEATURES AND CONTROLS Switches Mode Reverse Differential Override Switch Switch Engine Stop Switch C 3 Hazard 6 9 ft RAW i 7 33 EN A Y Headlight l S th 4X4 Switch Horn Switch Turn Signal Switch MIU NIU Mode Reverse Override Switch Press the switch to toggle through the speedometer display modes except in reverse See page 32 To gain additional power while operating in reverse press the override switch before opening the throttle This will cancel the reverse speed limit function NOTE The override switch also allows activation of 4X4 in reverse if the 4X4 switch is on A WARNING Activating the override switch while the throttle is open can cause loss of control resulting in severe injury or death
3. After the operator is seated the passenger should mount the vehicle from the left side NOTE Allow a passenger to ride only in the approved passenger seat with both feet on the footrests and both hands on the passenger grab han dles at all times The passenger should never hold on to the operator 8 Drive slowly Control may be more difficult with a passenger on board Allow more time and distance for braking 9 Avoid unexpected or aggressive maneuvers that could cause a pas senger to fall from the vehicle 10 Do not cross a hillside with a passenger on board See page 52 11 Never secure a passenger to the vehicle or to the operator with a belt rope or similar device 12 Make sure the passenger understands the importance of active riding When hill climbing or performing maneuvers a passenger should shift body weight in the same manner in which the driver shifts body weight For example the passenger should lean to the inside of a turn along with the operator and should always lean uphill when climbing and descending hills 49 OPERATION Driving Uphill 15 Maximum Whenever traveling uphill follow these precautions l peru es Oder 9 Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See page 31 Avoid steep hills 15 maximum Avoid hills with slippery or loose surfaces Keep both feet on the footrests Shift body weight uphill Drive straight uphill Proceed at
4. Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill Never back down a hill See page 54 Always follow the procedures outlined in this manual for operating over obstacles See page 59 Always follow the procedures outlined in this manual for operating on slippery or loose surfaces Use extra caution Always avoid skidding or sliding See page 58 Always follow the procedures outlined in this manual for driving through water Never drive through deep or fast flowing water See page 56 12 SAFETY Rider Safety Always follow the procedures outlined in this manual for driving in reverse See page 61 Always use the size and type of tires specified for your vehicle Maintain the proper tire pressure Never modify a Quadricycle through improper installation or use of accessories Never exceed the stated load capacity for your vehicle Cargo must be properly distributed and securely attached Reduce speed and follow the instructions in this manual for carrying cargo or towing Allow a greater distance for braking 13 SAFETY Rider Safety PIN Never operate the Quadricycle on a frozen body of water PIN Operating on paved surfaces may affect the handling and control of the Quadricycle and could result in loss of control Avoid sudden turns or swift movement of the handlebars PIN Always remove the ignition key when the vehicle is not
5. whether whole or in part is expressly prohibited Printed in U S A 2008 Sportsman 800 Touring Quadricycle Owner s Manual P N 9921454 2 TABLE OF CONTENTS Know Your Vehicle 5 SIEV ep 6 Features and Controls 20 ODGralloD 35 2 shrek cee ee EXER Sn 41 Emission Control Systems 64 Maintenance LL 65 SDecifiCcalloli8 voos RD D pes et 118 Polaris Products co REESE 120 Troubleshooting 121 rici A Tm 125 Maintenance Log 128 lus ecc cE 130 KNOW YOUR VEHICLE As the operator of the vehicle you are responsible for your personal safety the safety of others including your passenger and the protec tion of our environment Read and understand your owner s manual which includes valuable information about all aspects of your vehicle including safe operating procedures Ride responsibly Know all laws and regulations concerning the opera tion of this vehicle in your area Vehicle Identification Numbers Record your vehicle 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 Engine Serial Number Vehicle Model Number Frame VIN
6. Do not activate the override switch while the throttle is open 20 FEATURES AND CONTROLS Switches Main Key Switch eq End all electrical power to the vehicle LIGHTS ON position turns the headlights on Start the engine The headlights are not on in this position DO After starting the engine release the key switch to the POSITION LIGHTS ON position PIN Do not attach a large key fob or key ring to the main switch It may contact the gas tank cap when turning causing an interruption to the electrical system and an unexpected engine shut down during operation This could result in serious injury or death Engine Stop Switch Engine The engine will not start or run when Stop Switch the switch is in the OFF position K OFF E RUN Light Switch The lights do not operate unless the main key switch is on and the engine stop switch is in the RUN position High Beam AZ Low Beam 21 FEATURES AND CONTROLS Switches 4X4 Switch Cs 4X4 Switch Use the 4X4 switch to engage ADC 4X4 4X4 or 2X4 See page 30 Hazard Warning Switch Hazard Warning Differential A Push the hazard warning 7 Switch Switch switch to cause all turn Br signal lights to flash simultaneously Use this feature to alert others of an emergency or other situation requiring caution Turn Signal Switch lt i Push the toggle switch either left or right to activate the corresponding turn signal lig
7. Engine Serial Number Key Number SAFETY Rider Safety The following signal words and symbols appear throughout this manual and on your vehicle Your safety 1s involved when these words and sym bols are used Become familiar with their meanings before reading the manual A The safety alert symbol on your vehicle or in this manual alerts you to the potential for injury A WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death CAUTION The safety alert caution indicates a potential hazard that may result in minor 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 Rider Safety A WARNING Failure to follow the warnings in this manual can result in serious injury or death A Polaris Quadricycle is not a toy and can be hazardous to operate A collision or rollover can occur quickly even during routine maneuvers if you fail to take proper precautions Read and understand your owner s manual and all warnings before operating a Polaris Quadricycle Safety Training When you purchased your new Quadricycle your dealer offered a hands on safety training course You were also provided with printed materials that explain safe operating procedures Review this informa tion on a regular basis If you purchased a used Pol
8. Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc B drive poses Inspect clean replace worn Plane Ade B Front wheel 1600 Inspect replace as needed bearings Brake Brake fluid 3200 Change every two years oR fluid 200 H EE 2000 3200 Change every two years iu x 24 M 3200 Replace every 2 years more often under severe use Spark arrestor 300 36M 4800 Clean out out m adjustment ec er periodically adjust when parts are replaced a Headlight aim Adjust as needed P Perform these procedures more often for vehicles subjected to severe use E Emission Related Service B Have an authorized Polaris dealer perform these services 68 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 65 Items not listed in the chart should be lubricated at the General Lubrication interval NOTE The a arms and upper control arms are lubricated at the factory and no additional lubrication will be needed However if these components are subjected to severe use grease zerks have been provided for additional lubrication at the user s discretion Lube Capacity at Fluid Change Engine Oil PS 4 PLUS Performance 2 qt 1 9 I See page 70 Synthetic 2W 50 Brake Fluid DOT 4 Only ae See page 82 Transmission Oil Polaris AGL Synthetic 32 oz 948 ml
9. Recharge battery to 12 8 VDC Possible Lean Fuel Cause Solution Low or contaminated fuel Add or change fuel clean the fuel system Clogged fuel filter Replace filter Kinked or plugged fuel vent line Inspect and replace if equipped Possible Rich Fuel Cause Solution Fuel is very high octane Replace with lower octane fuel Stopping starting without adequate Allow engine to warm up before operat warm up ing and or stopping Replace with recommended fuc Clogged air filter Inspect and clean or replace 123 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution times for 5 seconds each then start Fouled or defective spark plug s Inspect clean and or replace spark plug s Worn or defective spark plug wires See your dealer Loose ignition connections Overheated engine Clean radiator screen and core clean engine exterior see your dealer Engine Overheating Possible Cause Solution Debris lodged in screen Remove and clean the screen Pull on the top portion of the screen then remove the lower portion Plugged Radiator Use a garden hose to flush any debris from the radiator fins NOTE High pressure washers can deform the radiator fins and reduce cooling efficiency 124 WARRANTY LIMITED WARRANTY Polaris Industries Inc 2100 Highway 55 Medina MN 55340 gives a TWO YEAR LIMITED WARRANTY on all components of the Polaris Quadricycle against defects in material or workmanship This
10. Transmission seals Brakes e Cab and body panels Labels and decals Electrical components and wiring NOTE f warning and safety labels are damaged contact your Polaris dealer for free replacement Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system Polishing the Vehicle Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle Follow the instructions on the container Polishing Tips Avoid the use of automotive products some of which can scratch the finish of your vehicle e Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 112 MAINTENANCE Cleaning and Storage Chrome Wheel Care if equipped Proper maintenance will protect chrome wheels from corrosion pre serve wheel life and ensure a like new appearance for many years NOTE Chrome wheels exposed to road salt or salt in the air in coastal areas are more susceptible to corrosion if not properly cleaned Clean chrome wheels more often if they re exposed to salt or other corrosive elements 1 Wash chrome wheels frequently Use a mild detergent Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elemen
11. a steady rate of speed to avoid stalling Be alert Be prepared to take emergency action This may include dismounting quickly Never open the throttle suddenly or make sudden gear changes 10 Never go over the top of a hill at high speed 50 OPERATION Driving Uphill If all forward speed is lost Keep your weight uphill If the vehicle begins rolling downhill never apply engine power Never apply the brakes aggressively while rolling backwards 1 Apply the brakes gradually 2 When fully stopped lock the hydraulic parking brake 3 A passenger should dismount first The operator should dismount last Dismount on the uphill side or on the left side if the vehicle is pointed straight uphill 4 Usethe K turn to turn around See page 54 A Always follow the procedures outlined in this manual for climbing hills Avoid climbing hills steeper than 15 rN Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill Never back down a hill 51 OPERATION Driving on a Sidehill Sidehilling Avoid crossing the side of a hill sidehilling if possible If sidehilling is necessary follow these precautions Slow down If operating in 2X4 mode make sure the differential is locked amp Avoid hills with slippery or loose surfaces Avoid crossing the sides of steep hills pA och ds Do not cross a hillside with a passenger on board Ask the pa
12. and longer life for these components Do not operate at full throttle or high speeds for extended periods during the first three hours of use Engine and Drivetrain Break in 1 Fill the fuel tank with the recommended fuel See page 28 2 Check the engine oil level See page 70 Add oil if necessary 3 Select an open area that allows room to familiarize yourself with vehicle operation and handling 4 Drive slowly Vary the throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 43 6 Pull only light loads 7 Change the oil and filter at one month PVT Break in Clutches Belt Break in the clutches and belt by operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggres sive acceleration and high speed operation during the break in period 42 OPERATION Pre Ride Checklist Steering steering lock Unlock Tm steering ensure free oper ation Inspect condition and pressure Wheels fasteners Inspect ensure fastener tightness Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels Coolant level if applicable Ensure proper level Coolant hoses if applicable Inspect for leaks Throttle Ensure proper operation Headlamp Check operation apply ae eee tric grease when lamp is replaced Brake light taillight Chec
13. 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 con sumption use of non recommended oil or incorrect throttle body adjust ments 98 MAINTENANCE Spark Plugs Spark Plug Removal A A hot exhaust system and engine can cause serious burns Wear protective gloves when removing a spark plug for inspection 1 Remove the spark plug cap 2 Use the spark plug wrench to remove the spark plug Turn the plug counterclockwise to remove it 3 Inspect the electrodes for a wear and carbon buildup Ay Replace worn or fouled T C plugs Verify that the gap is N N A at specification before Uh 3 installation 4 Reinstall the spark plug Torque to specification See page 98 5 Reinstall the spark plug cap 99 MAINTENANCE Vehicle Immersion If your vehicle has been totally submerged in water and it s impossible to have it serviced before further operation perform the following pro cedure A If the vehicle stops while fully submerged major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine 1 Move the vehicle out of the water 2 Remove the spark plug 3 Drain any water found in the air box 100 MAINTENANCE Vehicle Immersion 4 Turn the ignition key past the POSITION LIGHTS positi
14. hold on to the operator Always travel slowly when operating on unfamiliar terrain Use extra caution Use caution when operating on rough slippery or loose terrain Always follow the procedures outlined in this manual for turning See page 47 Never turn sharply at excessive speeds which can lead to vehicle overturn 10 SAFETY Rider Safety If a Quadricycle has been involved in an accident always have an authorized Polaris dealer inspect the entire vehicle for possible damage including but not limited to brake throttle and steering systems Always follow the procedures outlined in this manual for driving on hills See page 50 Never operate on hills too steep for the Quadricycle or for your abilities Practice on smaller hills before attempting larger hills Avoid climbing hills steeper than 15 Never operate with the differential unlocked 4 while operating on a hill or other irregular terrain See pages 23 and 31 Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill PIN Always follow the procedures outlined in this manual for driving downhill and for braking on hills See page 53 PIN Always follow the procedures outlined in this manual for crossing the side of a hill See page 52 Never attempt to turn the Quadricycle around on any hill until you ve mastered on level ground the turning technique outlined in this manual 1 SAFETY Rider Safety
15. in use to prevent unauthorized use or accidental starting PIN Always unlock the steering before starting the engine See page 27 A Hot components can cause serious burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system For more information about Quadricycle safety contact an authorized Polaris Quadricycle dealer or visit the Polaris web site at www polarisindustries com 14 SAFETY Safety Decals and Locations Warning decals have been placed on the vehicle for your protection Read and follow the instructions on each decal carefully If a 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 The following pages repeat the information found on each decal General Alert Multi Lingual Before you operate or ride this vehicle read the owner s manual Hill Operation Alert Never operate this vehicle on HILLS steeper than 15 degrees 15 To prevent flip over on hilly terrain when going up or down use throttle and brakes gradually Operation Alert 15 SAFETY Safety Decals and Locations Reverse Override Front Rack nen Warning N NSS Clutch Rear Rack 2S Cover Alert Warning Eg um z y E ean mv REO CO Ze IB Tire Pressure aa Load Alert Y f Tire Pressure Loa
16. is accidently ingested into the PVT system Dry it out before operating Position the vehicle on a level surface 2 Place the transmission in PARK 3 Remove the drain plug Allow the water to drain completely Rein stall the drain plug 4 Start the engine 5 Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches NOTE Do not hold the throttle wide open for more than 10 seconds 6 Allow the engine RPM to settle to idle speed then shift the trans mission to the lowest available range Test for belt slippage If the belt slips repeat the process 8 Take the vehicle to your dealer for service as soon as possible 105 MAINTENANCE Battery Your vehicle may have either a sealed battery which requires little maintenance or a conventional battery A sealed battery can be identi fied by its flat covers on the top of the battery A conventional battery has six filler caps on the top of the battery Always keep battery terminals and connections free of corrosion If cleaning is necessary remove corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the termi nals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into a conventional battery A WARNING Battery electrolyte is poisonous It contains sulfu
17. least 13 hours verify state of charge 096 2596 11 5 volts orless Needs charge with At least 20 hours desulfating charger 110 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components 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 1 Usea professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips e Avoid the use of harsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish 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 111 MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning not recommended exercise extreme caution The water may damage components and could remove paint and decals Avoid directing the water stream at the follow ing items Wheel bearings e Radiator e
18. marks 83 MAINTENANCE Brakes The front and rear brakes are hydraulic disc brakes activated by apply ing the foot brake The handlebar brake is also hydraulic Both brake systems are self adjusting Brake Inspections Perform the following checks to keep the brake systems in good operat ing condition Check more often if brakes are used heavily under normal operation 1 Always keep brake fluid at an adequate level See page 82 2 Check the brake systems regularly for fluid leaks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness Replace the pads when the friction material is worn to 1 mm 5 Check the security and surface condition of the disc 84 MAINTENANCE Toe Alignment A WARNING Do not attempt to adjust alignment All steering adjustments should be performed by an authorized Polaris dealer Use the following procedure to check the toe alignment of the vehicle The recommended toe alignment is 3 6 mm toe out Position the vehicle on a level surface 2 Place the handlebars in a straight ahead position 3 Tiealength of string between two stands as shown in the illustration Position the stands so that the string 1s flush with the side of the rear tire NOTE If available you may use a long straight edge instead of string 4 Measure the distance from the string to the rim at the front 1 and rear 2 of the fro
19. oil level in NOTE The oil level will read 7 8 the safe range Do not overfill higher on the bottom side of the dipstick Always read the level on the upper surface of the dipstick Reinstall the dipstick Secure the lever lock 71 MAINTENANCE Engine Oil Oil and Filter Change A CAUTION Hot oil may result in serious burns Do not allow hot oil to contact skin Position the vehicle on a level surface 2 Place the transmission in PARK 3 Start the engine Allow it to idle for 2 3 minutes 4 Stop the engine 5 Clean the area around the drain plug 6 Remove the drain plug Drain the oil into a drain pan 7 Clean the drain plug Reinstall the drain plug with a new sealing washer 8 Torque to specification See page 70 72 MAINTENANCE Engine Oil Oil and Filter Change 9 10 11 12 13 14 15 16 17 18 19 20 Place towels under the oil filter Using an oil filter wrench turn the filter counterclockwise to remove it Clean the filter sealing area on the crankcase Lubricate the filter o ring Check to make sure the o ring is in good condition AT Install the new oil filter After the filter contacts the crankcase surface turn it 1 2 turn by hand Remove the dipstick Add 1 9 liters of recommended oil Place the transmission in PARK Start the engine Allow it to idle for 1 2 minutes Stop the engine C
20. warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transferable to another consumer during the warranty period through a Polaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty THE PURCHASER MUST COMPLETE A QUADRICYCLE SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE QUADRICYCLE 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 WAR RANTY COVERAGE WILL BE ALLOWED UNLESS YOUR QUADRICYCLE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehicle is very important in ensuring trou ble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage 125 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
21. 2871823 2871534 2871312 2871322 2871423 2871460 2871518 2871661 2871329 2872073 2872348 2871326 2870652 2872189 2859044 Description 120 TROUBLESHOOTING Drive Belt Wear Burn Possible Cause Solution Driving onto a pickup or Use low range tall trailer in high range Starting out going up a Use low range or turn around using the K turn see page steep incline 54 Driving at low RPM or Drive at a higher speed or use low range more frequently ground speed 5 11 kmh Insufficient warm up at Warm the engine at least 5 minutes With the transmission low ambient tempera in neutral advance the throttle to about 1 8 throttle in tures short bursts 5 to 7 times The belt will become more flex ible and prevent belt burning Slow easy clutch engage Use the throttle quickly and effectively ment Towing pushing at low Use low range only RPM low ground speed Utility use plowing Use low range only Shift the transmission to low range Carefully use fast TURF throttle application to engage clutch Climbing over large etal PP objects from a stopped en M throttle may cause loss of control position Belt slippage from water Dry out the PVT See page 105 Inspect clutch seals for or snow ingestion into the damage if repeated leaking occurs PVT system Clutch malfunction malfunction SeeyourPolaisdeale SeeyourPolaisdeale Polaris dealer Poor engine E E Check for fouled plugs or foreign ma
22. MAINTENANCE Battery Battery Installation 1 Ensure that the battery is fully charged 2 Place the battery in the battery holder 3 With conventional batteries install the battery vent tube sealed bat teries do not have a vent tube NOTE The vent tube must be free of obstructions and securely installed Route the tube away from the frame and vehicle body to prevent con tact with electrolyte A WARNING Battery gases could accumulate in an improperly installed vent tube and cause an explosion resulting in serious injury or death Always ensure that the vent tube is free of obstructions and is securely installed as recommended 4 Onconventional batteries coat the terminals with dielectric grease or petroleum jelly 5 Connect and tighten the red positive cable first 6 Connect and tighten the black negative cable last 7 Install the battery cover if equipped 8 Secure the battery hold down strap 9 Verify that cables are properly routed NOTE Cables should be safely tucked away at the front and rear of the bat tery Battery Storage Whenever the vehicle is not used for a period of three months or more remove the battery from the vehicle ensure that it s fully charged and store it out of the sun in a cool dry place Check battery voltage each month during storage and recharge as needed to maintain a full charge NOTE Battery charge can be maintained by using a Polaris Battery Tender charger or by
23. N 42 44 45 46 FORTE 51 injector Circuit Malfunction Cyl 1 Open Load Shortto Ground 5i I 52 52 55 55 56 56 58 58 59 59 e 3s 72 73 ec ee 74 2 2 2 5 1 1 6 6 7 7 1 1 2 2 4 5 6 7 7 1 1 2 2 5 5 6 6 8 8 9 9 3 3 2 3 3 4 4 1 40 OPERATION Fuel Safety A WARNING Gasoline is highly flammable and explosive under certain conditions Use extreme caution whenever handling gasoline Refuel with the engine stopped Refuel outdoors or in a well ventilated area Never fill a fuel container while it s on the vehicle Static electricity between the rack and container could cause a spark 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 water and change clothing 4 OPERATION Break In Period The break in period for your new Polaris Quadricycle is the first ten hours of operation or the time it takes to use the first two full tanks of gasoline No single action on your part will increase the life and perfor mance of your Quadricycle more than following the procedures for a proper break in Careful treatment of a new engine and drive compo nents will result in more efficient performance
24. See page 74 Gearcase Lube Demand Drive Demand Drive LT Pre 9 3 oz 275 ml See page 76 Fluid Front mium Fluid Gearcase Polaris ADC Fluid See page 78 Front Prop Shaft Polaris Premium U Joint Grease fittings 3 Yoke Lube pumps maximum every 800 km before long periods of stor age or after pressure washing or submerg ing Front Prop Shaft Yoke 69 MAINTENANCE Engine Oil Oil Recommendations Always change the oil filter whenever changing oil Polaris recommends the use of Polaris PS 4 PLUS Performance Syn thetic 2W 50 4 cycle oil or a similar oil for this engine Oil may need to be changed more frequently if Polaris oil is not used Always use 2W 50 oil Follow the manufacturer s recommendations for ambient tempera ture operation A Mixing brands or using a non recommended oil may cause serious engine damage Always use a recommended oil Never substitute or mix oil brands Oil Specifications Lubricant Capacity Drain Plug Torque PS 4 PLUS Performance 1 9 as 53a 27 N m Synthetic 2W 50 4 Cycle Oil 70 MAINTENANCE Engine Oil Cil Level 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Lift the lever lock Remove the dipstick Wipe it dry with a clean cloth 4 Reinstall the dipstick epee completely but do not lock it 5 Remove the dipstick and Check Level check the oil level on the on Top Side top side of the dipstick 6 Maintain the
25. Under normal operation the diaphragm extends into the reservoir as fluid level drops If the fluid level is low and the diaphragm is not extended a leak is likely and the diaphragm should be replaced To ensure proper diaphragm operation always fill the reservoir as needed whenever the cover is loosened or removed Do not overfill A WARNING Never store or use a partial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of accident or severe injury After opening a bottle of brake fluid always discard any unused portion 82 MAINTENANCE Brake Fluid Hand Brake Indicator Window The master cylinder is Master located on the left handle bar Maintain the fluid level 6 mm below the top edge of the master cylinder Do not overfill 1 Position the vehicle on a level surface Make sure the handlebars are straight 2 View the fluid level through the indicator win dow eye on the top of the master cylinder NOTE The eye will appear dark when the fluid level is full When fluid is low the eye will be clear 3 Add the recommended fluid as needed Do not overfill Foot Brake Check the brake fluid level frequently for the foot brake system The reservoir 1s located under the seat Maintain the fluid level between the maximum and minimum
26. 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 Snowmobiles All terrain vehicles ATVs e Quadricycles e RANGER utility vehicles e Victory motorcycles Always follow the instructions and recommendations in this manual The manual contains instructions for minor maintenance but informa tion about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Please see your dealer for all of your service needs during and after the warranty period For more information about Polaris visit us online at www polarisindustries com Gl POLARIS The Way Out POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus tries Inc Copyright 2007 Polaris Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within
27. and Drive LT 275 ml 11 14 N m 15 N m Unit Premium Fluid Use the recommended fluid Use of other fluids may result in improper operation of components See page 120 for the part numbers of Polaris products Maintain the fluid level at Fill Plug the bottom of the fill hole Fill Level threads Fluid Level 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Remove the fill plug Check the fluid level 4 Add the recommended demand drive fluid as needed 5 Reinstall the fill plug Torque to specification 76 MAINTENANCE Front Gearcase Demand Drive Fluid Fluid Change 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Remove the fill plug 4 Remove the drain plug Drain the fluid into a drain pan 5 Clean the drain plug 6 Reinstall the drain plug Torque to specification See page 76 7 Add the recommended fluid 8 Reinstall the fill plug Torque to specification 9 Check for leaks 10 Discard used oil properly TI MAINTENANCE Active Descent Control ADC Fluid The ADC fluid reservoir is located under the front box The reservoir cap is yellow We recommend the use of Polaris ADC Fluid See page 120 for the part numbers of Polaris products Fluid Level 1 Position the vehicle on a level surface 2 Open the front box cover 3 Open the access door 4 View the fluid level in the reservoir 5 Remove the c
28. and tear abuse or improper handling This warranty also does not cover any Quadricycle that has been altered structurally modified neglected improperly maintained used for racing or used for purposes other than for which it was manufactured or for any dam ages 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 vehicle 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 Quadricycle The exclusive remedy for breach of this war ranty shall be at Polaris exclusive option repair or replacement of any defective materi als or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR RANTY 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 inconsisten
29. ap and add the recommended fluid as needed NOTE DO NOT use brake fluid 6 Maintain the fluid level between the minimum and maximum marks Do not over fill ADC Fluid Reservoir 78 MAINTENANCE Active Descent Control ADC Fluid Fluid Change 1 Position the vehicle on a level surface Before performing the fluid change allow the vehicle to sit for at least 30 minutes 2 Thoroughly clean the areas around and on the ADC reservoir and bleeder valves one on each side of the differential 3 Remove the reservoir cap and diaphragm assembly Use a shop towel or suction tool to remove debris from the fluid and reservoir NOTE Debris in the reservoir may result in inadequate bleeding and reduced A performance of the system Fill the reservoir to the maximum line with fresh ADC fluid Remove the protective caps from the bleeder valves Slowly loosen one of the valves turn counter clockwise and allow fluid and trapped air to flow from the fitting Close the valve when clean fluid begins to flow Repeat this step for the remaining valve IMPORTANT Close the bleeder valves before the reservoir fluid level drops below the minimum fill line Adding fluid to an empty reservoir will result in trapped air If the level drops below the minimum line add fluid to the maximum line and repeat step 6 before proceeding 7 8 Torque the valves to 9 N m Reinstall the valve caps Add fresh ADC fluid to the reservoir unti
30. aris Quadricycle from a party other than a Polaris dealer please request free safety training from any authorized Polaris dealer Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation 1s prohibited for anyone under 16 years of age Never allow anyone under 12 years of age to ride as a passenger on this 2 up Quadricycle Restrictions This vehicle is approved for OFF ROAD TOWING ONLY Operating a Quadricycle trailer combination on public roads is prohibited See your Polaris dealer about configuring the vehicle to be certified to tow a trailer on road Equipment Modifications The warranty on your Polaris Quadricycle may be terminated if any equipment has been added or if any modifications have been made that increase speed or power NOTE The addition of certain accessories including but not limited to mow ers blades tires sprayers and large racks may change vehicle han dling Use only Polaris approved accessories Know their function and effect on the vehicle SAFETY Rider Safety A WARNING Serious injury or death can result if you do not follow the instructions and procedures listed here and throughout this manual M M SS A Read and understand all warnings cautions and operating procedures in this manual and on the safety labels before operating the Quadricycle Never operate a Quadricycle without proper instruction Jake a training course Beginners shoul
31. bled it provides a convenient reminder to perform routine maintenance See page 37 NOTE The service interval is programmed at 50 hours at the factory 36 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Programmable service interval To enable or disable the service interval I 2 gt Enter the diagnostic mode Toggle to the service interval screen Press and hold the mode button for about 7 seconds until either ON or OFF appears in the Rider Information Center depending on your preference To reset the service interval l 2 3 4 Enter the diagnostic mode Toggle to the service interval screen Press and hold the mode button for 2 3 seconds until the wrench icon flashes Release the button Press and release the mode button once to advance the setting by one hour Press and hold the mode button to advance the hours quickly NOTE If you scroll past the intended number press and hold the button until 5 the hours cycle back to zero When the desired setting is displayed wait until the wrench icon stops flashing The new service interval is now programmed 37 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Miles Kilometers toggle The display in the tripmeter and odometer can be changed to display either standard or metric units of measurement 1 Enter the diagnostic mode 2 Toggle to the screen that displays
32. charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point See page 120 for the part numbers of Polaris products 108 MAINTENANCE Battery Battery Fluid Lower Upper Conventional Battery Mark Mark Check the battery fluid level often Maintain the fluid level between the upper and lower level marks Add only distilled water Tap water contains minerals that are harmful to a battery Battery Charging Conventional Battery 1 Remove the battery from the vehicle to prevent damage from leak ing or spilled electrolyte during charging See page 107 2 Charge the battery with a charging output no larger than 1 10 of the battery s amp hr rating Charge as needed to raise the specific grav ity to 1 270 or greater 3 Reinstall the battery See page 108 Make sure the positive terminal is toward the front of the vehicle Battery Charging Sealed Battery The following battery charging instructions apply only to the installa tion of a sealed battery Read all instructions before proceeding with the installation of this battery The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Never pry the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a seale
33. configuring the vehicle to be certified to tow a trailer on road Do not tow any trailer on a grade steeper than 15 Maximum Towing Capacities Maximum Towed Load Level Ground 680 kg Maximum Vertical Hitch Weight 68 kg A Using an improper hitch or exceeding the Maximum maximum tongue weight capacity can result 17 cm in serious damage to the vehicle and will void your warranty Never install a hitch longer than 17 cm Never install automotive accessories on your Polaris Quadricycle Always install Polaris approved or equivalent accessories designed for Quadricycle use 63 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine intake or exhaust components as doing so may affect compliance with governmental noise level requirements Spark Arrestor Your Polaris vehicle has a spark arrestor that was designed for on road and off road operation It is required that this spark arrestor remain installed and functional when the vehicle 1s operated Exhaust Emission Control System Exhaust emissions are controlled by engine design An electronic fuel injection EFI system controls fuel delivery The engine and EFI com ponents are set at the factory for optimal performance and are not adjustable Electromagnetic Interference This spark ignition system complies with USA requirements Canadian ICES 002 and European directives 89 336 EEC and 97 24 EC 64 MAINTENANCE Periodic Maintenanc
34. d Alert TIRE PRESSURE IN PSI KPa FRONT 5 34 5 REAR 5 34 5 MAXIMUM WEIGHT CAPACITY 568 LBS 258 kg INCLUDES WEIGHT OF OPERATOR PASSENGER CARGO AND ACCESSORIES Read Owner s Manual for more detailed loading information PIN Reverse Override Alert Pushing reverse override button may cause sudden increases in power and traction if too much throttle is applied Loss of control or forward flipover may result especially in 4X4 AWD See Owner s Manual 16 SAFETY Safety Decals and Locations A Rack Warning Front and Rear WARNING DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death Tow only from tow hooks or hitch Maximum Rack Loads Front 90 Ibs 41 kg Rear 180 Ibs 82 kg Clutch Cover Alert NO STEP 17 SAFETY Safe Riding Gear Always wear protective clothing to reduce the chance of injury Helmet Eye Protection Gloves Helmet Always wear a helmet that meets or exceeds established safety stan dards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has 051039 granted approval The approval number and serial 0006 31 number will also be displayed on the label 18 SAFETY Safe Riding Gear Eye Protection
35. d battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage 109 MAINTENANCE Battery Battery Charging Sealed Battery For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher 2 Ifthe voltage is less than 12 8 volts recharge the battery at 1 2 amps or less until battery voltage is 12 8 or greater NOTE When using an automatic charger refer to the charger manufacturer s instructions for recharging When using a constant current charger use the following guidelines for recharging A WARNING An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging NOTE Always verify battery condition before and 1 2 hours after the end of charging State of ENSE Time Voltage Using constant current Charge charger standard amps specified on top of battery Nul 12 8 13 0 volts None check at 3 None required mos from date of manufacture us 100 12 5 12 8 volts May need slight 3 6 hours charge if no charge given check in 3 months 5096 7596 7596 12 0 12 5 12 0 12 5 volts Needs Needs charge 5 11 S9 1hous EH 5096 11 5 12 0 ESI BI charge Hen E
36. d receive training from a certified instructor Contact an authorized Polaris Quadricycle dealer or visit the Polaris web site at www polarisindustries com Never permit others to operate the Quadricycle unless they have read and understand this manual and all product labels and have completed a certified safety training course A Never allow anyone under 16 years of age to operate this vehicle Never allow anyone under 12 years of age to ride as a passenger on this 2 up Quadricycle Never carry more than one passenger on this 2 up Quadricycle SAFETY Rider Safety Always wear an approved helmet that fits properly Wear eye protection goggles or face shield gloves boots long sleeves and long pants Never consume alcohol or drugs before or while operating a Quadricycle Never operate at excessive speeds Travel and turn at speeds appropriate for the terrain visibility operating conditions and your experience Never attempt jumps or other stunts SAFETY Rider Safety Always inspect your Quadricycle before each use to verify that it s in safe operating condition Follow the inspection and maintenance procedures outlined in this manual See page 43 Keep both hands on the handlebars Keep both feet on the footrests A passenger should always be seated in the passenger seat with both feet on the footrests and both hands on the passenger grab handles at all times The passenger should never
37. e Chart Maintenance intervals in the following chart are based upon average riding conditions Vehicles subjected to severe use must be inspected and serviced more frequently The programmable service interval mode on the instrument cluster will help determine when maintenance service is due See page 32 Record maintenance and service in the Maintenance Log beginning on page 128 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 Severe Use Definition Frequent immersion in mud water or sand e Racing or race style high RPM use Prolonged low speed heavy load operation e Extended idle e Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crank case Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer 65 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key P Perform these operations more often for vehicles subjected to severe use E Emission related service M Have an authorized Polaris dealer perform these services A WARNING Improperly performing the procedures marked with a lil could result in component failure and lead to serious
38. e pre cleaner and air filter See page 92 Clean the air box Clean or replace the breather filter See page 93 AUN Drain the sediment tube 114 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 65 e Demand drive unit front gearcase e ADC fluid change every two years Rear gearcase if equipped e Transmission Brake fluid change every two years and any time the fluid looks dark or contaminated e Coolant test strength fill Fog the Engine 1 Treat the fuel system with Polaris Carbon Clean See page 114 2 Remove the spark plug Pour 30 45 ml of engine oil into the plug holes 3 Reinstall the spark plug Torque to specification 4 Apply dielectric grease to the inside of each spark plug cap Rein stall the caps 5 Turn the engine over several times Oil will be forced in and around the piston rings and ring lands coating the cylinder with a protec tive film of fresh oil 6 If Polaris fuel system additive is not used the fuel tank fuel lines and injectors should be completely drained of gasoline 115 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 65 Battery Storage See pages 108 109 for storage and charging pr
39. e turned on or off while the vehicle is moving 4X4 will not engage until engine speed is below 3100 RPM 4X4 remains engaged until the switch is turned off There is no limit to the length of time the vehicle may remain in 4X4 If the switch is turned off while the demand drive unit is engaged it will not disengage until the rear wheels regain traction Engage 4X4 before getting into situations where maximum traction 1s needed If the rear wheels are spinning release the throttle before switching to 4X4 A Switching to 4X4 or ADC 4X4 while the rear wheels are spinning may cause severe drive shaft and gearcase damage Always switch to 4X4 or ADC 4X4 while the rear wheels have traction or are at rest Active Descent Control ADC System The ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill Engaging Active Descent Control The ADC system will automatically engage when all four of the follow ing conditions occur e The 4X4 switch must be in the ADC 4X4 position e Vehicle speed must be 24 km h or less The throttle must be closed throttle lever released e The transmission must be in gear high low or reverse Disengaging Active Descent Control The ADC system will automatically disengage if at least one of the fol lowing conditions occur e The 4X4 switch is moved out of the ADC 4X4 position Vehicle s
40. eel slightly off the ground Remove the wheel nuts Remove the wheel Place the wheel on the hub Install the wheel nuts finger tight Lower the vehicle to the ground Torque the wheel nuts to specification See torque chart on page 90 91 MAINTENANCE Air Filter Always clean and replace the air and breather filters at the intervals out lined in the Periodic Maintenance Chart beginning on page 65 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Remove the seat 4 Releasethe air box cover clips 5 Remove the air box cover 6 Loosen the hose clamp Pre Filter 7 Remove the filter Main Filter 8 Remove the pre filter from the filter 9 Wash the pre filter in soapy water Rinse and air dry NOTE Replace the filter if needed 10 Reverse the steps to reinstall all components 92 MAINTENANCE Breather Filter Hose 4 Ds The breather filter is on the hose between the engine and air box l Remove the left side panel See page 87 Remove the hose clamps from the filter and pull the filter out of the hoses Inspect the filter for debris Blow gently through the filter in the direction of the arrow to check Cw for clogging Replace a damaged Breather Filter or clogged filter Check the hoses for cracks deterioration abrasion or leaks Replace as needed Reinstall the filter and hose clamps NOTE The filter is effecti
41. either kilometers KM or miles 3 Press and hold the mode button until the letters flash then press and release the button once When the display stops flashing the mode has been set Downloading Codes The EFI diagnostic mode is for informational purposes only Please see your Polaris dealer for all major repairs See page 40 for Blink Codes and Failure Descriptions Use the follow ing procedure to download blink codes failure codes from the EFI module 1 Place the transmission in PARK Stop the engine Turn the key switch to the ON position 2 Turn the key switch off and on three times in less than five seconds The word WAIt will appear on the screen 38 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes 3 The Check Engine icon will blink once pause then blink twice blink code 12 to begin the diagnostic sequence The EFI module is now searching for blink codes If a code exists the Check Engine icon will flash the code 4 Count the number of times the Check Engine icon flashes Example For the two blink codes 42 and 36 the Check Engine icon will flash 4 times pause then flash 2 times code 42 then pause longer blink 3 times pause and blink 6 times code 36 5 A code 61 will signal the end of the sequence If no blink codes are found only codes 12 and 61 will appear during the sequence NOTE The word WAIt will remain on the screen through this en
42. ep your weight uphill Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See page 31 Lock the hydraulic parking brake Leave the transmission in forward gear Turn the engine off A passenger should dismount first The operator should dismount last Dismount on the uphill side or on the left side if the vehicle is pointed straight uphill Stay uphill of the vehicle and turn the handlebars full left Squeeze the brake lever to release the parking brake Slowly release the brake lever and allow the vehicle to roll around to your right until it s pointing across the hill or slightly downward OPERATION Turning Around on a Hill K Turn 9 Lock the hydraulic parking brake 10 Remount from the uphill side Keep your weight uphill NOTE A passenger should not remount until the vehicle returns to level ground 11 Apply the foot brake 12 With the transmission still in forward start the engine 13 Squeeze and release the brake lever to release the parking brake 14 Release the foot brake and drive slowly downhill Control speed with either the hand or foot brake until the vehicle is on level ground PIN Always follow the procedures outlined in this manual for climbing hills Avoid climbing hills steeper than 15 A Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill Never back down a hill 55 OPERATION Driving Thro
43. eze the brake lever toward the handlebar to apply the all wheel brakes If the rear wheels begin to skid or slide while using the brake reduce lever pressure A WARNING Aggressively applying the brakes when backing down a hill may cause rear tipover Aggressively applying the brakes while moving forward may cause the rear wheels to skid and result in loss of control Head this owner s manual and understand the operation of all brake systems on this vehicle Always use caution whenever applying the brakes 25 FEATURES AND CONTROLS Parking Brake Locking the Parking Brake 1 Place the transmission in PARK 4 2 Squeeze the brake lever toward the L AN Si handlebar p NY Wier 3 Push the parking brake lock forward to V AIN 1 i 77 engage the lock Release the brake LE lever 4 Torelease the parking brake lock squeeze and release the brake lever A WARNING Operating the Quadricycle while the parking brake is engaged could result in an accident and serious injury or death Always release the parking brake lock before operating 26 FEATURES AND CONTROLS Steering Lock Lock the steering to prevent unau thorized use or theft of the vehicle Turn the handlebars to the full right position NOTE The handlebars may also be locked in the full left position 2 Insert the steering lock key and turn it clockwise 9m A 3 Remove the key NOTE Place the steering lock keys in a safe p
44. g includes operator passen ger cargo accessories Dry Weight 795 Ibs 361 kg Front Rack Storage Box Capacity 90 Ibs 41 kg Rear Rack Capacity 180 Ibs 82 kg Receiver Hitch Tongue Capacity tongue weight not to exceed 180 Ibs 82 kg Unbraked Trailer Towing Capacity Overall idis Wheelbase Ground Clearance Minimum Turning Radius Demand Drive Fluid Capacity Transmission Oil Capacity Fuel System Lubrication System Driving System Type Automatic PVT Polaris Variable Transmis sion Front Suspension MacPherson strut with 8 2 21 cm travel Rear Suspension Progressive rate with 8 75 22 cm travel Based on EU Directive 76 432 EC 118 SPECIFICATIONS Sportsman 800 Touring Quadricycle w E Z Shift H L N R P Gear Reduction Reverse Tires Pressure Rear 25x11 12 5 psi 34 5 KPa Brake Hand All wheel hydraulic disc Brake Foot All wheel hydraulic disc Brake Parking Transmission park lock and hydraulic lock all wheel Clutching EBS Models Altitude Shift Drive Clutch Driven Helix Weight Spring Clutch Spring 1800 3700 21 70 6000 12000 PN 5632127 PN 3234604 Meters 0 1800 21 74 66 56 33 Feet 0 6000 PN 5632117 Red Blue Red BA500 PN 7043372 PN 3234452 EBS NOTE EBS models require no helix spring adjustment 119 POLARIS PRODUCTS Part Number 287078 2876244 2876245 2873602 2873603 2876144 Active Descent Control ADC Fluid 2871658 2872276 2870465 267625
45. he latch is not working properly do not allow a passenger to ride the vehicle See your Polaris dealer for service To remove the seat pull the latch loop at the rear of the seat Pull the seat upward to remove it from the vehicle To reinstall the seat make sure the rubber feet at the base of the seat are positioned in the rear rack Press down firmly on the seat pad until the latch clicks 20 FEATURES AND CONTROLS All Wheel Drive 4X4 System The All Wheel Drive system is controlled by the 4X4 switch ADC 4X4 When the switch is on ADC 4X4 the ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See page 31 4X4 When the switch 1s on 4X4 the vehicle 1s in 4X4 and the 4X4 indicator light in the instrument cluster will be on When in 4X4 the demand drive unit will automatically engage any time the rear wheels lose traction When the rear wheels regain traction the demand drive unit will automatically disengage There is no limit to the length of time the vehicle may remain in 4X4 NOTE The override switch allows activation of 4X4 in reverse if the 4X4 switch is on See page 20 2X4 When the switch is on 2X4 the vehicle is in two wheel drive at all times ADC 4x4 4x4 2x4 30 FEATURES AND CONTROLS All Wheel Drive 4X4 System Engaging 4X4 The 4X4 switch may b
46. heck for leaks Check the oil level Add oil as needed Maintain the oil level in the safe range Do not overfill Discard used oil and filter properly 73 MAINTENANCE Transmission Oil Maintain the oil level at the bottom of the fill plug hole threads Use the recommended oil See page 120 for the part numbers of Polaris products Transmission Oil Recommendations Lubricant Oil Change Fill Plug Drain Plug Capacity Torque Torque Premium AGL Synthetic 948 ml 30 N m 30 N m Gearcase Lubricant Transmission Oil Level Position the vehicle on a level surface 2 Place the transmission in PARK 3 Remove the fill plug 4 Checkthe oil level Add the recommended oil as needed Do not overfill 5 Reinstall the fill plug Torque to specification 74 MAINTENANCE Transmission Oil Transmission Oil Change l 2 9 10 Check for leaks 11 Discard used oil properly Position the vehicle on a level surface Place the transmission in PARK Remove the fill plug Remove the drain plug Drain the oil into a drain pan Clean the drain plug Reinstall the drain plug Torque to specification See page 74 Add the recommended oil See page 74 Reinstall the fill plug Torque to specification See page 74 75 MAINTENANCE Front Gearcase Demand Drive Fluid Fluid Recommendations Gearcase Lubricant Capacity Fill Plug Drain Plug Torque Torque Demand Drive Dem
47. ht The indicator on the pod will also flash Return the toggle to the center position and push it inward to end the signal Turn Signal Horn Switch Switch Horn Switch b Press the horn switch to sound the horn 22 FEATURES AND CONTROLS Switches Differential Switch Use the differential switch to lock and unlock the rear differential Locked Differential Operate the vehicle with the switch in o the locked position in most conditions Unlocked Differential When the differential 1s unlocked the fe inside wheel will rotate independently from the outside wheel during turns Operate with an unlocked differential only as needed to protect smooth level surfaces from tire damage Otherwise move the switch to the locked position This feature will function only if the vehicle is in 2X4 mode A Operating with the differential unlocked 4 when on sloped uneven or loose terrain could cause loss of control and result in serious injury or death One rear wheel may slip and lose traction or may lift up and grab when it touches the ground again DO NOT operate with the differential unlocked 4 when climbing or descending hills when sidehilling or when operating on uneven loose or slippery terrain such as sand gravel ice snow obstacles and water crossings Place the differential switch in the locked position and operate in ADC 4X4 or 4X4 on these types of terrain 23 FEATURES AND CONTROLS Throttle Lever Pres
48. ined in this manual for turning Never turn sharply at excessive speeds which can lead to vehicle overturn Before turning activate a turn sig nal to alert others of your inten tions Activate the left signal before a left turn Activate the right signal before a right turn Steer 1n the direction of the turn leaning your upper body to the inside of the turn while support ing your weight on the outer foot rest Use the same leaning technique for turning in reverse Never turn quickly when carrying a passenger or cargo Practice making turns at slow speeds before attempting to turn at faster speeds A 47 OPERATION Driving with a Passenger A Never allow anyone under 16 years of age to operate this vehicle Never allow anyone under 12 years of age to ride as a passenger on this 2 up Quadricycle Never carry more than one passenger on this 2 up Quadricycle 1 Make sure the passenger is at least 12 years of age and is tall enough to comfortably reach the footrests and grab handles 2 Make sure the passenger is wearing appropriate riding gear including an approved helmet with a rigid chin guard See page 18 3 Perform the pre ride inspection See page 43 4 Always make sure the passenger Seat is installed and securely latched before operating with a passenger 5 Place the transmission in PARK 48 OPERATION Driving with a Passenger 6 Mount the vehicle from the left side 7
49. injury or death Have an authorized Polaris dealer perform these services Perform all services at whichever maintenance interval 1s reached first Maintenance Interval whichever comes first Hours Calendar Kilometers peso menia Pre Ride Ride E EE adjustments as need ny F DERE See Pre Ride Checklist Front suspension Prende onpageas Rear suspension RreRde es Rene Brake Tuidievel Prefi Brake lever Pre Ride Foxbrke PreRide Brake system PeRide Passenger seat Pre Ride latch Whessasenes Pene e NN Engineoillevel oil level a ER pre filter Daily Inspect clean often replace as needed ie Air box sediment aa a Drain deposits when visible tube Coolant Daily Check level daily change coolant every 2 years M ME fluid DEN BENE level daily add as A a a eR Ead Check operation apply dielectric grease if replacing lamps 66 MAINTENANCE Periodic Maintenance Chart Maintenance Interval whichever comes first EL E puro A PEE MEN LLL LLL replace as needed E main puro A Ld pad wear a Monthly a periodically Battery 20 Monthly 320 Check terminals clean test bees drive Devo diet 25 Monthly 400 E s level Inspect level change yearly yearly D gearcase oil Monthly E 2 A level change yearly if equipped Transmission oil oil 25 Monthl
50. k operation apply Polaris dielec tric grease when lamp is replaced Riding gear Wear approved helmet goggles and protective clothing ADC Fluid Ensure proper level Cono CO NN oo O O 43 OPERATION Starting the Engine A WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death Never run an engine in an enclosed area A Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Sit on the vehicle NOTE The starter interlock will prevent the engine from starting if the trans mission is in gear and the brake is not engaged 4 Move the engine stop switch to Mar NOTE Do not press the throttle while starting the engine 5 Turn the ignition key past the POSITION LIGHTS ON position to engage the starter Activate the starter for a maxi mum of five seconds releasing the key when the engine starts 500 EFI ONLY The starter will automatically stop if engaged for longer than 5 seconds Move the key to the OFF position and wait 10 seconds before engaging the starter again 6 If the engine does not start release the starter and wait five seconds 7 Repeat steps 5 and 6 until the engine starts 44 OPERATION Cold Weather Operation Internal engi
51. l the level is between the minimum and maximum marks Make sure the reservoir is free of debris Reinstall the cap securely Clean up any drips or spills 79 MAINTENANCE Cooling System Any time the cooling system has been drained for maintenance or repair replace the coolant with a fresh mixture of antifreeze and water Drain the cooling system every two years Add fresh coolant Polaris recommends the use of Polaris Premium 60 40 anti freeze cool ant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water Polaris Premium 60 40 is premixed and ready to use Do not dilute with water See page 120 for the part num bers of Polaris products NOTE Always follow the manufacturer s mixing recommendations for the freeze protection required in your area Recovery Bottle Coolant Some coolant level drop on new machines is p normal as the system is purging itself of trapped air Add coolant as needed NOTE Check the coolant level in the radiator any time the recovery bottle has run dry Add coolant as needed Check the coolant level when the fluid 1s cool 2 Remove the left side panel See page 87 NOTE Maintain the coolant level between the minimum and maximum marks on the bottle when the fluid is cool 3 View the coolant level 4 Add coolant as needed 5 Reinstall the side panel 80 MAINTENANCE Cooling System Radiator Coolant A WARNING Esca
52. lace The lock must be replaced if the keys are lost 4 Reverse the procedure to unlock the steering A The handlebars are locked in the fully turned position when the steering is locked Always unlock the steering before starting the engine 21 FEATURES AND CONTROLS Fuel Tank Cap Remove the fuel tank cap to add fuel to the fuel tank Use Fuel Tank G3 either leaded or unleaded gaso Cap B BN line with a minimum pump octane of 87 Do not use E 65 fuel Fuel Filter The in line fuel filter should be replaced by your dealer after every 100 hours of operation or annually Do not attempt to clean the fuel filter 28 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector G is located on the right side of EE ON the vehicle H High Gear NC L Low Gear N Neutral R Reverse P Park Whenever the vehicle is left unattended always place the transmission in PARK The transmission is locked when it s in PARK PIN Shifting gears with the engine speed above idle or while the vehicle is moving can cause transmission damage Stop the vehicle release the throttle and move the shift lever to the desired gear See your dealer if you experience any shifting problems Passenger Seat Always make sure the passenger seat is installed and securely latched before operating with a passenger Test the seat latch by attempting to pull the seat upward NOTE Ift
53. lose traction Be alert Watch the trail Avoid quick sharp turns EN C em Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward 7 Never apply the brakes during a skid PIN Always follow the procedures outlined in this manual for operating on slippery or loose surfaces Use extra caution Always avoid skidding or sliding PIN Severe damage to drive train may occur if 4X4 is engaged while the wheels are spinning Engage 4X4 when the wheels have traction 58 OPERATION Driving Over Obstacles Always check for obstacles before operating in a new area Be alert Watch the terrain Use extra caution Never operate over large obstacles Avoid hazards such as logs rocks and low branches pue e Ie Always have a passenger dismount before operating over an obsta cle A Always follow the procedures outlined in this manual for operating over obstacles 59 OPERATION Parking on an Incline ores XT tentent mmt er Avoid parking on an incline If it s unavoidable follow these precau tions 1 Stop the engine 2 Place the transmission in PARK 3 Always block the rear wheels on the downhill side 60 OPERATION Driving in Reverse Follow these precautions when operating in reverse l IR EE CE Always check for obstacles or people behind the vehicle before backing Be aware that a passenger can obstr
54. n PARK 2 Open the front rack cover 3 Remove the plug at the back of the headlight 4 Pullthe harness plug to disconnect it from the back of the headlight 5 Position light Rotate the socket to remove it Go to step 6 Headlamp Reach under the bumper and remove the rubber cover from the back of the headlight Turn the collar counter clockwise and carefully remove the collar and socket Position Light Sal Headlamp 6 Remove the lamp Apply dielectric grease to the socket and install a new lamp 7 Reverse all steps to reassemble the headlight 95 MAINTENANCE Lights Taillight Lamp Replacement Place the transmission in PARK 2 Rotate the taillight socket counterclockwise to remove it 3 Remove the lamp 4 Apply dielectric grease to the socket 5 Install the new lamp Test the lamp for proper operation 6 Reinstall all components in reverse order Front Turn Signal Lamp Replacement Place the transmission in PARK 2 Remove the lens attachment screw 3 Rotate the lamp to remove it 4 Install the new lamp 5 Reinstall the lens Rear Turn Signal Lamp Replacement 1 Place the transmission in PARK 2 Rotate the turn signal socket counterclockwise to remove it 3 Remove the lamp 4 Apply dielectric grease to the socket 5 Install the new lamp Test the lamp for proper operation 6 Reinstall all components in reverse order 96 Fuse Replacemen
55. ne condensation increases as outside temperatures decrease If the vehicle is used year round check the oil level fre quently A rising oil level could indicate condensation in the bottom of the oil tank which can lead to engine damage Any condensation must be drained Always operate the engine long enough to reach operating temperature which reduces condensation See your Polaris dealer for engine heater kits which provide quicker warm ups and easier starting in cold weather PVT Operation When To Use Low Range and High Range Condition Range to Use Operating at speeds less than 11 km h Towing heavy loads Operating in rough or rugged terrain Operating at speeds greater than 11 km h High 45 OPERATION Driving Procedures acce nem dE E E Wear protective riding gear See page 18 Perform the pre ride inspection See page 43 Place the transmission in PARK Mount the vehicle from the left side Sit upright Keep your feet on the footrests Keep both hands on the handlebars Start the engine and allow it to warm up Apply the brakes Shift the transmission into gear Check your surroundings and determine your path of travel 10 Release the brakes 11 Slowly squeeze the throttle lever toward the handlebar to begin driving 12 Drive slowly Practice maneuvering and using the throttle and 46 brakes on level surfaces OPERATION Turning the Vehicle Always follow the procedures outl
56. nt rim The rear measurement should be 2 3 mm more than the front mea surement on each side of the vehicle to obtain the recommended 3 6 mm toe out alignment 5 Repeat the measurement procedure on the other side of the vehicle NOTE f you discover improper alignment see your Polaris dealer for service 85 MAINTENANCE Handlebar Adjustment The handlebars can be adjusted for rider preference A WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars resulting in loss of control Follow the adjustment procedures exactly or see your Polaris dealer for service 1 Remove the upper headlight pod 2 Loosen the four handlebar bolts 3 Adjust the handlebar to the desired height NOTE Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right 4 Torque the front two bolts to 14 17 N m then torque the rear two bolts A gap of up to 3 mm will remain at the rear of the clamp blocks Steering Assembly Check the steering assembly of the vehicle periodically for loose nuts and bolts If loose nuts and bolts are found see your Polaris dealer for service before operating the vehicle Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counterclockwise to increase or decrease spring tension
57. nter of gravity of the vehicle and creates a less stable operating condition Reduce load weight when cargo is high Secure off centered loads that cannot be centered and operate with extra caution CARRYING A LOAD on only one rack may cause the vehicle to overturn Split the load between the front rack and rear rack with 1 3 in the front and 2 8 in the back Do not exceed load capacities See specifications beginning on page 118 e SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle e USE EXTREME CAUTION when operating with loads that extend over the rack sides Stability and maneuverability may be adversely affected causing the vehicle to overturn TOWING is approved OFF ROAD ONLY Operating a Quadricycle trailer combination on public roads is prohibited TOWING SPEED should never exceed 16 km h Never exceed 8 km h when towing loads in rough terrain while cornering or while ascending or descending hills 62 OPERATION Hauling Cargo Towing Loads Towing is approved OFF ROAD ONLY Operating a Quadricycle trailer combination on public roads is prohibited See your Polaris dealer about
58. o the specifications section beginning on page 118 for recom mended tire type size and pressure A WARNING Operating your vehicle with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident Maintain proper tire pressure as described on the decal on your vehicle and in the specifications section of the owner s manual Use only original equipment size and type when replacing tires Make sure the wheels are installed properly Replace tires when the tread depth measures 3 mm or less Tire Tread Depth Always replace tires 3 mm when tread depth is worn to 3 mm or less 9 NS Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical com ponent operations All service must be performed by your authorized Polaris dealer 89 MAINTENANCE Tires Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loos ened for maintenance service Cast Aluminum Steel Nut Type Nut Torque Lug Nut 122 Nm 90 MAINTENANCE Tires A Always use original equipment size and type when replacing tires Install wheels properly Wheel Removal Installation l 2 10 Position the vehicle on a level surface Place the transmission in PARK Loosen the wheel nuts slightly Place a suitable stand under the footrest frame to raise the wh
59. ocedures Storage Area Covers 1 Set the tire pressure and safely support the vehicle with the tires slightly off the ground 2 Besure the storage area 1s well ventilated 3 Cover the vehicle with a genuine Polaris cover Do not use plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation Accessories Auxiliary power outlets provide 12 volt power for operating accesso ries Accessory outlets are available for all models Polaris also has a wide range of additional accessories available for your vehicle Always install accessories that are approved for Quadricycle use Please see your Polaris dealer 116 MAINTENANCE Transporting the Vehicle Follow these procedures when transporting the vehicle l 2 3 Stop the engine Place the transmission in PARK Secure the fuel cap oil cap and seat Remove the key to prevent loss during transporting i S it Always tie the frame of the Quadricycle to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets Towing a Disabled Vehicle If towing the vehicle is necessary shift the transmission into neutral for better mobility and to prevent damage to the belt Always attach the tow rope to the frame of the Quadricycle 117 SPECIFICATIONS Sportsman 800 Touring Quadricycle Maximum Weight Capacity 568 Ibs 258 k
60. on to engage the starter Engage the starter for only 2 3 seconds Dry the spark plug Reinstall the plug or install a new plug Torque to specification See page l 98 Attempt to start the engine If necessary repeat the drying procedure Have the vehicle serviced by your dealer promptly whether you succeed in starting it or not NOTE If water has been ingested into the PVT follow the procedure on page 105 for drying out the PVT 101 MAINTENANCE Spark Arrestor Occasionally the spark arrestor may accumulate carbon which can restrict the exhaust if left unattended Purge the spark arrestor A WARNING Allow components to cool sufficiently before servicing The exhaust system can get extremely hot Never run the engine in an enclosed area or indoors Exhaust contains poisonous carbon monoxide gas Never go under the vehicle while it s inclined Remove any combustible materials from the area Wear eye protection and leather work gloves Do not stand behind or in front of the vehicle while purging Position the vehicle on a level surface 2 Place the transmission in PARK 3 Remove the arrestor clean out plug from the bottom of the muffler 4 Start the engine 5 Quickly squeeze and release the throttle lever several times to purge car bon from the system 102 MAINTENANCE Spark Arrestor 6 10 11 If carbon comes out of the exhaust cover or plug the exha
61. peed exceeds 24 km h The throttle is open throttle is applied e The transmission is shifted to neutral or park 3l FEATURES AND CONTROLS Instrument Cluster The instrument cluster senses vehicle speed from the transmission The instrument cluster measures distance in miles or kilometers as well as hours of operation It also includes a reverse speed limiter function that limits the vehicle s speed to approximately 11 14 km h Refer to page 20 for additional information Speedometer Needle Speedometer v DO Hider Information P amp LARIS Center NOTE In addition to showing vehicle speed the speedometer needle flashes when a warning condition exists rN High water pressure may damage vehicle components Wash the vehicle by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage the speedometer lens and other plastic surfaces Do not use alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens Immediately clean off any gasoline that splashes on the instrument cluster 22 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster All seg ments will light up for 2 5 seconds at start up NOTE Ifthe instrument cluster fails to illuminate a battery over voltage may DN aS have occurred and the instrument cluster may have shut off to p
62. ping steam can cause severe burns Never remove the pressure cap while the engine is warm or hot 1 Open the front box cover 2 Open the access door 3 Remove the radiator pressure cap 4 If coolant is not visible slowly add coolant through the radiator filler neck 5 Reinstall the pressure cap 6 Secure the access door and box cover NOTE Use of a non standard pressure cap will not allow the recovery system to function properly Contact your dealer for the correct replacement part 81 MAINTENANCE Brake Fluid Check brake fluid levels for both brake systems before each ride Always maintain brake fluid at the recommended level Do not overfill The brakes should feel firm when they re applied Spongy or weak brakes may indicate a fluid leak or low fluid level A low fluid level may also mean that brake pads are worn and need to be replaced Do not operate the vehicle with spongy or weak brakes See your dealer for ser vice A WARNING Operating the Quadricycle with a spongy brake can result in loss of braking which could cause an accident Never operate the Quadricycle with spongy feeling brakes If the fluid level is low add DOT 4 brake fluid only See page 120 for the part numbers of Polaris products A WARNING An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill
63. ric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN 106 MAINTENANCE Battery A WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last Battery Removal Place the transmission in PARK Disconnect the battery hold down strap Remove the battery cover if equipped On conventional batteries remove the battery vent tube Disconnect the black negative battery cable first Disconnect the red positive battery cable last DOM CM Mm Lift the battery out of the vehicle Be careful not to tip a conven tional battery sideways which could spill electrolyte NOTE If electrolyte spills immediately wash it off with a solution of one table spoon baking soda and one cup water to prevent damage to the vehi cle 107
64. rotect the electronic speedometer If this occurs take the vehicle to your Polaris dealer for proper diagnosis Gear Indicator This 3 4 5 6 indicator displays gear shifter position H High Gear L Low Gear N Neutral R Reverse Gear P Park 2 4X4 Indicator This indicator illuminates when the 4X4 switch is on either ADC 4X4 or 4X4 Engine Hour Display Indicator Service Interval Diagnostic Mode Indicator Odometer Tachometer Tripmeter Hour Meter Clock Fuel Gauge The segments of the fuel gauge show the level of fuel in the fuel tank When the last segment clears a low fuel warning is activated All segments will flash FUEL will display in the LCD and the speedometer needle will blink Refuel immediately Check Engine Warning Indicator This indicator serves two pur poses The word HOT displays 1f the engine overheats It also appears if an EFI related fault occurs Do not operate the vehicle if this warning appears Serious engine damage could result Mode Indicator 33 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes Use the MODE button to toggle through the mode options The reverse override button is also the MODE button See page 20 NOTE The transmission cannot be in reverse when using this feature Odometer Mode The odometer records the miles or kilometers traveled by the Quadricy cle Trip Meter Mode The trip meter records the miles or kilometer
65. s the throttle lever to increase engine speed and vehicle move ment Release the lever to reduce engine speed and vehicle move ment A WARNING Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation Check the lever for proper operation before starting the engine Check occasionally during operation Do not start or operate a Quadricycle with sticking or improperly operating throttle controls Contact your dealer for repair if throttle problems arise Mirrors Use the mirrors to assist in traffic maneuvers Always check and adjust the mirrors before driving the Quadricycle Electronic Throttle Control ETC ETC causes the engine to Electronic Throttle Control stop if the throttle cable sticks in an open position when the operator releases the throttle lever A The Electronic Throttle Control ETC stops the engine in the event of a throttle system malfunction Do not modify the ETC system or replace it with other throttle mechanisms 24 FEATURES AND CONTROLS Foot Brake The all wheel foot brake is located on the right footrest The foot brake operates both front and rear brakes Press the brake pedal down with your foot to apply the all wheel brakes If the rear wheels begin to skid or slide while using the foot brake reduce brake pressure Hand Brake Lever The hand brake operates both front and rear brakes Sque
66. s traveled by the Quadricy cle on each trip if it s reset before each trip To reset the trip meter select the trip meter mode Press and hold the mode button override button until the total changes to O NOTE In the Rider Information Center the trip meter display contains a deci mal point but the odometer displays without a decimal point Hour Meter Mode This mode logs the total hours the engine has been in operation Tachometer Mode The engine RPM is displayed digitally NOTE Small fluctuations in the RPM from day to day may be normal because of changes in humidity temperature and elevation Clock Mode The clock displays time in a 12 hour format To reset the clock see page 35 34 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when the gauge is in the diagnostic mode To exit the diagnostic mode turn the key switch off and on Any move ment of the tires will also cause the gauge to exit the diagnostic mode To enter the diagnostics mode 1 Turn the key switch off and wait 10 seconds 2 Lock the parking brake 3 Place the transmission in neutral 4 Hold the mode reverse override button and turn the key switch on Release the switch as soon as the display is activated 5 Use the mode button to toggle through the diagnostic screens Clock Screen To reset the clock 1 Enter the diagnostic mode 2 Toggle to the clock screen 3 Pre
67. ss and hold the mode button until the hour display flashes Release the button 4 Press and release the mode button once to advance the setting by one hour Press and hold the mode button to advance the hours quickly 5 When the desired hour is displayed wait approximately four sec onds until the minute display flashes 6 Use the same procedure to reset the minutes 7 When the display stops flashing the mode has been set NOTE Do not turn the key switch off until the display stops flashing or the new setting will not be locked into the memory 35 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Battery Voltage Screen View this screen to check battery voltage level Tachometer Screen View the tachometer to check engine speed 4X4 Diagnostic Screen The gauge indicates whether or not current is flowing through the 4X4 coil only on models with switchable 4X4 This screen is for informa tional purposes only Please see your dealer for all major repairs Gear Circuit Diagnostic Screen This screen displays the resistance value 1n ohms being read at the gear switch input of the gauge This screen is for informational purposes only Please see your dealer for all major repairs Programmable service interval When the hours of engine operation equal the programmed service interval setting the wrench icon will flash for 5 seconds each time the engine is started When this feature is ena
68. ssenger to dismount and walk across the hillside 6 Shift your weight uphill 7 Keep your feet on the footrests 8 Steer slightly into the hill NOTE Ifthe vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately A Always follow the procedures outlined in this manual for crossing the side of a hill Never attempt to turn the Quadricycle around on any hill until you ve mastered on level ground the turning technique outlined in this manual 52 OPERATION Driving Downhill When driving downhill follow these precautions 1 Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See page 31 2 Avoid hills with slippery or loose surfaces 3 Never drive downhill at high speed Slow down 4 Drive straight downhill Avoid driving downhill at an angle which can cause the vehicle to pitch sharply to one side 5 Shift your weight rearward 6 Apply the brakes slightly to aid in slowing A Always follow the procedures outlined in this manual for driving downhill and for braking on hills A Never operate at excessive speeds Travel and turn at speeds appropriate for the terrain visibility operating conditions and your experience 53 OPERATION Turning Around on a Hill K Turn If the vehicle stalls while climbing a hill never back it down the hill Use the K turn to turn around 54 Stop the vehicle Ke
69. t If the engine stops or will not start or if you experience other electrical fail ures a fuse may need replacement NOTE Spare fuses are provided in a compartment on the top of the access door 1 Open the front box cover 2 Open the access door 3 Remove the suspect fuse from the fuse panel Install a new fuse with the same amperage 4 Secure the access door 5 Secure the box cover MAINTENANCE 97 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 118 for the recom mended spark plug type and gap for your vehicle Torque spark plugs to specification Plug Condition Torque Specification New Spark Plug 12 15 N m Previously Installed Spark Plug 23 27 N m Spark Plug Inspection Spark plug condition is indicative of engine operation Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color Normal Spark Plug The normal insulator tip is tan or 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 throttle body adjustments Wet Fouled Spark Plug The wet fouled insulator tip is black A
70. t with controlling state law ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE TWO YEAR WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limi tations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law 126 WARRANTY HOW TO OBTAIN WARRANTY SERVICE If your Quadricycle requires warranty service you must take it to a Polaris dealer autho rized to repair Polaris Quadricycles When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANS PORTATION 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 127 MAINTENANCE LOG Present this section of your manual to your dealer each time yo
71. terial in gas tank or fuel lines See your dealer Slippage from failure to Always warm up the belt by operating below 48 km h for warm up belt 1 6 km Operate 8 km or more when temperature is below freezing Wrong or missing belt Install the recommended belt Improper break in Always break in a new belt and or clutch See page 42 121 TROUBLESHOOTING Engine Does Not Rotate Possible Cause Solution Low battery voltage Recharge the battery to 12 8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Engine Rotates Fails to Start Possible Cause Solution Out of fuel Refuel Water is present in fuel Engine Backfires Possible Cause Solution Weak spark from spark plug Inspect clean and or replace spark plug s Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel SE Loose ignition connections See your dealer See your dealer 122 TROUBLESHOOTING Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Runs Irregularly Stalls or Misfires Possible Cause Solution Fouled or defective spark plug s Inspect clean and or replace spark plug s See your dealer Set gap to specs or replace plugs
72. tire process Code Definitions Open Load There is a break in the wires that lead to the item listed in the chart injector fuel pump etc or the item has failed Short to Ground The wire 1s shorted to ground between the electronic control unit and the item listed in the chart Shorted Load The wires leading to the item listed 1n the chart are shorted together or the item has shorted internally Short to Battery The wire leading from the item listed in the chart to the electronic control unit is shorted to a wire at battery voltage 39 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Blink Failure Description Code 2 2 2 3 3 3 3 3 3 5 51 Injector Circuit Malfunction Cyl 1 Shorted Load Short to Batiery 52 Injector Circuit Malfunction Cyl 2 Open Load Shorio Ground 52 Injector Circuit Malfunction Cyl 2 Shorted Load Short to Battery 55 MIL Circuit Open Load Short to Ground 55 MIL Circuit Shorted Load Shortto Battey 56 Fuel Pump Open Load Shortto Ground 56 Fuel Pump Shorted Load Shortto Battery F 58 Fan Circuit Open Load Shortto Ground 58 Fan Circuit Shorted Load Shortto Battery 59 ADC OpenLoad Shoio Groun 5 ADC Shorted Load Short to Battery 1 4 4 4 4 4 4 4 4 4 6 6 7 7 7 7 7 E 22r E ES oie 31 36 36 MERC oa at i EU
73. ts can cause corrosion 3 Polish the clean chrome wheels periodically Use an automotive grade chrome polish 4 Routinely and liberally apply a weather resistant wax to each pol ished chrome wheel Choose a product suitable for chrome finishes Read and follow the product labels and instructions Removing Corrosion If light rust is found on the chrome finish use steel wool 0000 OTT grade to remove it Gently rub the affected areas with the steel wool until the corrosion has been removed Clean and polish the wheel as out lined above 113 MAINTENANCE Cleaning and Storage Storage Tips A 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 111 Stabilize the Fuel Fill the fuel tank 2 Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer Follow the instructions on the container for the recommended amount NOTE Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust sys tems 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the entire fuel delivery system Cil and Filter Change the oil and filter See page 72 Air Filter Air Box 1 Inspect and clean or replace th
74. uct your view Avoid backing downhill Drive slowly Apply the brakes ightly for stopping Avoid turning at sharp angles Never open the throttle suddenly Do not use the override switch unless additional power is required for vehicle movement Use with caution A 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 A Always follow the procedures outlined in this manual for driving in reverse 61 OPERATION Hauling Cargo A Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability Always follow these precautions when hauling cargo e Read and understand the load distribution warnings listed on the vehicle warning labels Never exceed the stated load capacity for this vehicle Never carry cargo on the rear rack when operating the ATV in the 2 up mode with a passenger e REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO OR TOWING Use extreme caution when applying brakes Avoid situations that require backing downhill e When operating over rough or hilly terrain reduce speed cargo and towed load to maintain stable driving conditions DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the front rack e CARRY LOADS AS LOW ON THE RACK AS POSSIBLE Carrying a load high on the rack raises the ce
75. ugh Water Follow these procedures when driving through water l 2 a 4 56 Check water depth and current before crossing Choose a crossing where both banks have gradual inclines Drive slowly Avoid rocks and obstacles Avoid operating in water deeper than the bottom of the footrests If it s unavoidable travel slowly balance your weight carefully and avoid sudden movements Maintain a slow and steady forward motion Do not make sudden turns stops or throttle changes Wet brakes may have reduced stopping ability Dry the brake pads by driving slowly and applying the brakes lightly several times until braking action is normal OPERATION Driving Through Water If your vehicle becomes fully immersed and it s impossible to take it to a dealer before starting it follow the steps described on page 100 Have the vehicle serviced by your dealer promptly A Always follow the procedures outlined in this manual for driving through water Never drive through deep or fast flowing water A If the vehicle stops while fully submerged major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine 57 OPERATION Driving on Slippery Surfaces Whenever driving on slippery or loose surfaces such as wet trails gravel snow or ice follow these precautions 1 Slow down before driving onto slippery surfaces 2 Engage 4X4 before wheels begin to
76. ur vehicle is serviced This will provide you and future owners with an accurate log of maintenance and ser vices performed DATE KILOMETERS TECHNICIAN SERVICE PERFORMED COMMENTS OR HOURS 128 KILOMETERS OR HOURS MAINTENANCE LOG TECHNICIAN SERVICE PERFORMED COMMENTS 129
77. ust outlet Wear protective gloves Lightly tap on the exhaust pipe with a rubber mallet while repeat ing step 5 If particles are still suspected to be in the muffler elevate the rear of the vehicle 30 cm higher than the front Block the wheels Place the transmission in aw PARK Repeat steps 5 to 7 until 30 cm no more particles are expelled Stop the engine Allow the arrestor to cool Reinstall the arrestor plug and remove the exhaust outlet cover or plug 103 MAINTENANCE PVT System A Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at a high speed The PVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures See your dealer as outlined in the owner s manual This PVT system is intended for use on Polaris products only Do not install it in any other product e Always make sure the PVT housing is securely in place during operation 104 MAINTENANCE PVT System PVT Drying There may be some instances when water
78. ve with the arrow pointing in either direction A Operation of your vehicle without a breather filter can cause engine damage 93 MAINTENANCE Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward 1 Position the vehicle on a level surface The headlight should be approximately 7 6 m from a wall 2 Place the transmission in PARK 3 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height NOTE Include rider weight on the seat when measuring 4 Start the engine Turn the head Screw light switch to high beam 5 Observe the headlight aim on the wall The most intense part of the headlight beam should be 5 cm below the mark on the wall 6 Tighten or loosen the lower headlight screws to adjust the beam upward or downward or to the left or right 94 MAINTENANCE Lights A WARNING Poor lighting can result in loss of control or an accident Lights become dirty during normal operation Wash the headlights and taillights frequently Hot components can cause serious burns to skin Do not service the headlamps until they ve cooled Headlight Position Light Lamp Replacement When servicing a halogen lamp do not 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 Hold the plastic part of the lamp 1 Place the transmission i
79. y 400 Inspect level Inspect level change yearly yearly E enema breather ENL ah clean eue e EE o needed filter if equipped Engine oil change Perform a break in oil change break in at one month General Lubricate all fittings pivots lubrication cables etc Shift linkage 50 6M 800 i nspect lubricate adjust w Seeing so 6M 800 Lubricate do 2 1 Rearsuspension Rear suspension _ 800 Lubricate lau cable Ro erac um adjust lubricate ETC switch replace if necessary IAS me Inspect duct for proper seal Fe duct ing air leaks e belt BAN ee adjust replace as BUM ed Loe system 1600 Inspect coolant strength seasonally pressure test system yearly hl oon oil change a Perform a break in oil change NN one month id cl filter Oil filter change 100 1600 Replace with oil Replace with oil change ka tank vent hose ECE ECE a routing condition if equipped 67 MAINTENANCE Periodic Maintenance Chart Maintenance Interval whichever comes first LIEN M I E clearance 12 RN es Inspect TTA Hiis system 12 Boii Wa stica MN for leaks at tank cap lines filter pump replace lines every 2 years ee Bud Inspect clean external NE ee b imm Cooling hoses 1600 Inspect for leaks Engine mounts mounts 100 12 12M _ 1600 Inspect Laur E m 12 a Inspect pipe E cR l plug 12 EN BE Inspect replace as needed E 12 Kad BE

Polaris 800 EFI Touring Quadricycle Offroad Vehicle User Manual

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