Home

JVC KS-F350R Cassette Player User Manual

1. Install a new sealing washer on the oil drain plug NOTE The sealing surfaces on the drain plug and on the oil tank should be clean and free of burrs nicks or scratches Reinstall the drain plug Torque to 14 17 ft Ibs 19 23 Nm Disconnect the lower oil delivery hose Remove the fitting C from the oil tank Clean the fitting screen Reinstall the fitting screen torquing to 14 17 ft Ibs 19 23 Nm Reattach oil line Torque hose clamp E to 25 in Ibs Place shop towels beneath the oil filter Using an oil filter wrench turn the filter counterclockwise to remove Using a clean dry cloth clean the filter sealing surface on the crankcase 87 MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change 4 Cycle Engines With External Oil Tank 11 Lubricate the gasket on the new filter with a film of new engine oil Make sure the gasket is in good condition Also make sure the gasket from the old filter is not still on the engine 12 Install the new filter 1 and tighten by hand 1 2 to 3 4 turn after the gasket contacts the engine 13 Approximately one cup of engine oil will remain in the crankcase sump To drain remove the drain plug on the lower right side of the crankcase 4 CAUTION Loss of oil pump prime could result in engine damage It s extremely important to drain refill and start the engine in an expedient manner Do not allow the engine to sit without oil for extende
2. Remove the lamp 1 and replace it with a new lamp Test the taillight brakelight to see that it s working Reinstall the gasket and lens cover Indicator Lamp Replacement 1 2 3 Remove the instrument panel if necessary to access the back of the indicator panel Using a small straight blade screwdriver turn the base of the bulb 1 4 turn counterclockwise Using a needle nose plier or similar tool pull the lamp out of the indicator panel housing Insert the new bulb and seat it by turning it 1 4 turn clockwise Reassemble the pod or front cover 125 MAINTENANCE AND LUBRICATION Spark Plugs Refer to your owner s manual supplement for recommended spark plug and gap specifications CAUTION Using non recommended spark plugs can result in serious engine damage Always use Polaris recommended spark plugs Spark plug condition is indicative of engine operation The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color AWARNING A hot exhaust system and engine can cause serious burns Wear protective gloves when removing a spark plug for inspection 1 Normal The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service
3. gt POLARIS The Way Out 2003 ATV Universal Owner s Manual for Vehicle Maintenance and Safety Read this manual carefully It contains important safety information This is an adult vehicle only Operation is prohibited for those under 16 years of age Z WARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm We ve created a web site just for YOU Technical tips New product introductions Event schedules Parts and Service Manual information Exciting details about The Way Out Check it out www polarisindustries com owner POLARIS The Way Out All information in this manual is based on the latest product data and specifications available at the time of printing Polaris Industries Inc reserves the right to make product changes and improvements that may affect illustrations or explanations No part of this manual shall be reproduced or used without the written permission of Polaris Industries Inc Copyright 2002 Polaris Industries Inc All Rights Reserved Printed in the U S A 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 Polaris Recreational and Utility Vehicles e Snowmobiles e All terrain vehicles ATVs e Personal watercraft e Victory motorcycles e RANGER utility vehicles
4. 144 Kinked or plugged fuel vent line Inspect and replace TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Kinked or plugged fuel vent line Water present in fuel Overuse of choke Fouled or defective spark plugs Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Clogged air filter Reverse speed limiter malfunction Electronic throttle control malfunction Other mechanical failure Overheated engine Clean radiator screen and core if equipped Clean engine exterior See your Polaris dealer 145 WARRANTY LIMITED WARRANTY Polaris Industries Inc 2100 Highway 55 Medina MN 55340 gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle ATV against defects in material or workmanship Polaris also gives a one year limited warranty on the final drive chain for failure due to defects This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transferrable to another consumer during the warranty period through a Polaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty THE PURCHASER MUST COM
5. MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance Maintenance Servicing Servicing Interval Date Dealer Performed or Person 10 hrs 84 MAINTENANCE AND LUBRICATION Lubrication Recommendations Polaris 2 Cycle Lubricants Polaris Premium 2 cycle lubricants are the most advanced formulation of oils specifically designed for today s 2 cycle engines Our ongoing lab and field tests have resulted in a new generation of 2 cycle lubricants Polaris Premium 2 cycle lubricants provide additives for 2 cycle engines lacking in today s fuel These necessary additives keep ring grooves cleaner for less ring sticking and improved overall engine cleanliness With new generation lubricity technology Polaris oils excel in meeting the lubrication demands of today s high performance 2 cycle engines These optimum oils are recommended for liquid cooled and air cooled 2 cycle engines Polaris Premium 2 cycle oils will readily mix with each other but do not mix Polaris Premium 2 cycle oils with any other brand of oil including our Nature Oil Biodegradable oil Their incompatibility could result in engine damage See page 141 for the part numbers of Polaris recommended products Premium Gold Synthetic 2 Cycle Oil Your vehicle has been primed with Premium Gold Synthetic oil This lubricant has been specially formulated for low smoke low odor and high lubricity Prem
6. NOTE The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetion adjustments 2 Wet Fouled The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended injection oil improper use of the choke or incorrect carburetion adjustments Spark Plug Removal and Replacement 1 Remove the spark plug cap 2 Using the special wrench provided in the tool pouch rotate the spark plug counterclockwise to remove 3 Reverse the procedure for spark plug installation Torque to 14 ft Ibs 19 Nm 126 MAINTENANCE AND LUBRICATION Vehicle Immersion CAUTION If your vehicle becomes immersed major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine If it s impossible to take your ATV to a dealer before starting it follow the steps outlined below 1 Move the ATV to dry land or at the very least to water below the foot rests 2 Check the airbox for any water and dry it if water is present 3 Turn the fuel valve off 4 Remove the spark plug 5 Loosen the carburetor drain screw 1 or remove the bowl drain 2 6 For two cycle engines remove the crankcase drain screw See page 97 for the loca
7. 11 12 Roll the ATV forward or backward to adjust the chain slack to the proper tension See the illustration for proper splice link clip opening position 1 Tighten the eccentric locking bolts to 30 ft Ibs 41 Nm for machines without the hitch and 45 ft Ibs 61 Nm for machines with a hitch Tighten the caliper mount bolts to 10 12 ft Ibs 14 17 Nm Remove the pin punch Roll the ATV forward checking chain tension in several places around the chain NOTE The chain is adjusted correctly when the tightest portion of the chain has approximately 3 8 10mm deflection Position the chain guide to allow 1 8 3mm clearance and tighten the retaining bolt to 5 ft lbs 7 Nm Reinstall the chain guard if applicable 117 MAINTENANCE AND LUBRICATION Filter Systems Air Filter Removal and Service 2 Cycle Engines Remove the ATV seat Release the clips securing the cover assembly to the air box Loosen the clamp securing the filter and remove the filter Remove the foam pre filter from the main filter Wash the pre filter in soapy water then rinse and let dry ON AY Pe Oat Re install the pre filter over the main filter Replace the main filter if needed Air Filter Installation 2 Cycle Engines 1 Check the condition of the air box and replace if necessary 2 Replace the filter over the carburetor boot Make sure the filter is fully seated in the air box 3 Tighten the clamp Do not overtigh
8. ATV is a high performance vehicle for off road use only in sport type recreation and competitive use by operators with advanced skills and substantial experience Trail Blazer models 32 SAFETY Safety Decals and Locations 4 WARNING A WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY Operating this vehicle if you are under the age or DEATH of 16 increases your chance of severe injury or death NEVER operate this vehicle if you are under NO PASSENGER PASSAGERS INTERDITS A WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE PSI FRONT REAR __ MAXIMUM WEIGHT CAPACITY Gross Vehicle Weight INCLUDING MACHINE DRIVER AND CARGO IS LBS Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your risk of losing control Loads should be centered carried as low as possible and firmly secured to the racks with dual racks load distribution 1 3 front 2 3 rear is best For stability on rough or hilly terrain reduce speed and cargo Do not block headlight Be careful if load extends over the side of the rack Read Owner s Manual for more detailed loading information See your Owner s Manual Supplement for specifications 33 SAFETY Safety Decals and Locations A WARNING DO NO
9. If all forward speed is lost Keep your weight uphill Apply the single lever brake gradually When fully stopped apply the auxiliary brake as well then lock the park brake If the ATV begins rolling backwards Keep your weight uphill Never apply engine power Never apply the auxiliary rear brake while rolling backwards Apply the single lever brake gradually When fully stopped apply the auxiliary rear brake as well and then lock the parking brake Dismount on uphill side or to either side if ATV is pointed straight uphill Turn the ATV around and remount following the procedure described on page 69 pt asian 25 Maximum AWARNING Braking and handling are greatly affected when operating in hilly terrain Improper procedure could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 25 maximum Use extreme caution when operating on hills and follow proper operating procedures outlined in the owner s manual 66 OPERATION Driving Safely Sidehilling AWARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn resulting in severe injury or death Avoid crossing the side of a hill when possible Follow proper procedures as outlined in the owner s manual Sidehilling can be a dangerous type of driving and should be avoided if at all possible If you do enter into a situation where sidehilling is nece
10. Rinse with water frequently and dry with a chamois to prevent water spots NOTE If warning and safety labels are damaged contact your a Polaris dealer for free replacement Polaris does not recommend the use of a high pressure type car wash system for washing the ATV If a high pressure system is used exercise extreme care to avoid water damage to the wheel bearings transmission seals body panels brakes and warning labels NOTE Grease all zerk fittings immediately after washing and allow the vehicle to run for a while to evaporate any water that may have entered the engine or exhaust system Waxing the ATV Your ATV can be waxed with any non abrasive automotive paste wax Avoid the use of harsh cleaners since they can scratch the body finish CAUTION Certain products including insect repellants and chemicals will damage plastic surfaces Use caution when using these products near plastic surfaces 137 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips See page 141 for the part numbers of Polaris recommended products CAUTION Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur Never start the engine during the storage period Clean the Exterior Make necessary repairs and then clean the ATV thoroughly with mild soap and warm water to remove all dirt and grime Don t use harsh detergents or high pressure washers Some detergents dete
11. WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner s manual Always check the terrain carefully before ascending any hill Never operate the ATV on hills steeper than 25 Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly while traveling uphill The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill 23 SAFETY Operator Safety 24 4 WARNING POTENTIAL HAZARD Traveling downhill improperly WHAT CAN HAPPEN Improperly descending a hill could cause loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner s manual NOTE A special technique is required when braking while traveling downhill See page 68 Always check the terrain carefully before you descending a hill Shift your weight backward Never travel down a hill at high speed Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when possible SAFETY Operator Safety A WARNING POTENTIAL HAZARD Improperly crossing hills and turning on hills WHAT CAN HAPPEN Imprope
12. installed and used according to approved instructions See your authorized Polaris ATV dealer for more information 29 SAFETY Operator Safety 30 4 WARNING POTENTIAL HAZARD Overloading the ATV or carrying towing cargo improperly WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling which could lead to loss of control or an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow a greater distance for braking Always follow the instructions in the owner s manual for carrying cargo or pulling a trailer See page 61 4 WARNING POTENTIAL HAZARD Operating on frozen bodies of water WHAT CAN HAPPEN Severe injury or death can result if the ATV and or the operator fall through the ice HOW TO AVOID THE HAZARD Never operate the ATV on a frozen body of water If you re confident that the ice is thick enough and sound enough to support the machine and its operator as well as the force created by a moving vehicle exercise extreme caution SAFETY Operator Safety AWARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death Always remove the ignition key when the vehicle is not in use AWARNING After any overturn or accident have a qualified service dealer inspect t
13. s auxiliary brake system is intended to be used as a backup for the main brake system Should the main system fail the rear brake can be activated by depressing the foot pedal on the inside of the right footrest The hydraulic auxiliary brake system will not need adjustment 3 64 1 cm NOTE Since this is a rear brake only it will not be as effective as the all wheel single lever system 105 MAINTENANCE AND LUBRICATION Adjustments AWARNING Severe injury or death can result from improper toe alignment and adjustment Do not attempt to adjust tie rod alignment All tie rod adjustments should be performed by an authorized Polaris dealer Toe Alignment Use the following procedure to check the toe alignment of the vehicle The recommended toe alignment is 1 8 to 1 4 toe out 1 Set the handlebars in a z ee straight ahead position exes i NOTE The steering frog SL Lop N can be used as an indicator 8537 of whether the handlebars are See straight The frog should S7 always point straight back from the steering post 2 Place stands 1 in front of the vehicle perpendicular to the rear tires See illustration 3 Tie an elastic string around the stands making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in front of the vehicle 2 4 Measure the distance from the string to the rim at the 1 front and rear of the front
14. s instructions for recharging When using a constant current charger use the following guidelines for recharging AWARNING An overheated battery could explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging NOTE Always verify battery condition before and 1 2 hours after the end of charging State of Voltage Charge Time Charge Using constant current charger standard amps specified on top of battery 100 12 8 13 0 volts None check at None required 3 mos from date of manufacture 50 75 12 0 12 5 volts Needs Charge 5 11 hours 75 100 12 5 12 8 volts May need slight 3 6 hours charge if no charge given check in 3 months 5 50 11 5 12 0 volts Needs Charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs Charge At least 20 hours 136 MAINTENANCE AND LUBRICATION Cleaning and Storage See page 141 for the part numbers of Polaris recommended products Cleaning the ATV Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components With a few precautions your ATV can be cleaned much like an automobile Washing the ATV The best and safest way to clean your ATV is with a garden hose and a pail of mild soap and water Use a professional type washing mitten cleaning the upper body first and the lower parts last
15. 12 months Replace annually Radiator 100 hrs 12 months Inspect clean external sur face Cooling system 100 hrs 12 months Inspect hoses gt Front hubs AWD 100 hrs Change fluid annually Clutches drive and 100 hrs 12 months Inspect clean driven E Valve clearance 100 hrs 12 months Inspect adjust 4 Cycle Shift selector box 200 hrs 24 months Change lubricant every two H L R years Brake fluid 200 hrs Change every two years Front wheel bear 300 hrs 36 months Inspect replace as needed ings 2WD Recoil housing As required Drain moisture out after rid ing in water Fi Toe adjustment A i j Headlight aim gt More often under severe use such as dirty or wet conditions Emission Control System Service California E Dealer service item s required Periodic inspection adjust when parts are replaced Adjust as needed 79 MAINTENANCE AND LUBRICATION Lubrication Recommendations NOTE Hours are based on 10 mph average If service is due at 20 hours the equivalent odometer reading would be 200 miles Perform all services at whichever reading is reached first Lubrication Chart Key p gt More often under severe use such as wet or dusty conditions Polaris Premium All Season Grease or grease conforming to NLG No 2 such as Conoco Superlube M or Mobilegrease Special e Use Polaris Premium U Joint Lube every 500 miles before long periods of storage or after pr
16. Polaris at 1 800 342 3764 to find out about the training courses nearest you Never allow anyone under 16 years of age to operate this ATV Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safe ty training course Always avoid operating an ATV on paved surfaces including side walks driveways parking lots and streets Never operate an ATV on a public street road or highway including a dirt or gravel road Never operate an ATV without wearing an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots a long sleeved shirt or jacket and long pants Never consume alcohol or drugs before or while operating an ATV Never operate at excessive speeds Travel at speeds appropriate for the terrain visibility and operating conditions and your experience Never attempt wheelies jumps or other stunts Always inspect your ATV before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and schedules outlined in your owner s manual Always keep both hands on the handlebars and both feet on the foot rests of the ATV during operation Always travel slowly and use extra caution when operating on unfa miliar terrain Be alert to changing terrain conditions Never operate on excessively rough slippery or loose terrain Always follow proper turning procedures
17. Refer to your owner s manual supplement for model specific information 74 MAINTENANCE AND LUBRICATION Accessories Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights Accessory outlets are available for all models Contact your Polaris dealer for more information Polaris has a wide range of additional accessories available for your ATV See your Polaris dealer Periodic Maintenance Schedule Careful periodic maintenance will help keep your vehicle in the safest most reliable condition Inspection adjustment and lubrication of important components are explained in the periodic maintenance schedule Some models are equipped with a speedometer that has a programmable service interval mode This important feature will help you determine when maintenance service is due See page 54 for instructions Maintenance intervals in the following charts are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use such as operation in wet or dusty areas should be inspected and serviced more frequently Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use genuine Polaris parts available from your Polaris dealer NOTE Service and adjustments are critical If you re not familiar with safe service and adjustment procedures have a qualified de
18. TO AVOID THE HAZARD Never attempt wheelies jumps or other stunts Avoid exhibition driving SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the owner s manual 4 WARNING POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation WHAT CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV If the operator s foot is not firmly planted on the footrest it could come into contact with the rear wheels and lead to accident or injury HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation 19 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamili
19. Towing Gapachues 66sec nhadnwe ewes da we 61 Transmission Gear Selector 46 Transmission Oil Change 2x4 Models Transmission Oil Change Models w Fill Plug 92 on Oil Change Sportsman 94 on Oil Check Models w Dipstick 93 Transmission Oil Check Models w Fill Plug 91 Transporting the ATV 00 140 Trip Metets maus Aa oe dye die Seed hs aaao 53 TROUBLESHOOTING 142 145 Turning Around ona Hill 000 69 U USFS Approved Spark Arrestor 74 Vv VEHICLE IDENTIFICATION NUMBERS 6 Vehicle Immersion 000 00 127 Warning Read Your Owner s Manual 7 WARRANTY eeseesessessessoesoseo Wae serra aa eSa Washing the ATV 000005 Waxing the ATV oresar esemete ia WELCOME yoan E Ea ETERA E 6a ea Baek Wheel Installation Wheel Nut Torque Specifications 113 Wheel Removal ccc ccsvevasceevediatds ee 112 AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER Operate without proper training or instruction Operate on public roads A collision can occur with another vehicle e Operate at speeds too fast for your skills or the conditions e Use ALCOHOL or DRUGS before or while operating this vehicle Carry Passengers AL
20. ap ply Polaris dielectric grease to connector when replaced 76 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Hours Frequency Miles Taillight brakelight Pre Ride Pre Ride Check operation daily ap ply Polaris dielectric grease to socket when replaced p gt Air filter Weekly Weekly Inspect replace as needed main element Transmission oil 20 hrs Monthly Inspect monthly change level annually Battery 20 hrs Monthly Check terminals clean check fluid level Engine counterbal 20 hrs Monthly Check oil level change ance 400 Engines annually p gt Engine breather 20 hrs Monthly Inspect replace annually filter 4 cycle and as needed m Brake pad wear Monthly Inspect periodically Front and rear 100 hrs Monthly Check monthly change gearcase oil shaft annually drive Engine cylinder 25 hrs 3 months Inspect re torque required head and cylinder at first service only base fasteners General lubrication 50 hrs 3 months Lubricate all fittings pivots cables etc Engine oil level oil 100 hrs 6 months Check level daily break in change 4 Cycle 1000 service at one month miles change oil more often in cold weather Oil Filter 4 Cycle 100 hrs 6 months Replace with oil change 1000 mi Oil Pump Cable 50 hrs 6 months Inspect adjust lubricate 2 Cycle replace if required Engine breather 100 hrs 6 months Inspect hose 4 cycle gt More often under severe use such as dirty or we
21. areas outlined on the daily pre ride inspection checklist See page 58 6 Pull only light loads 7 During the break in period change both the oil and the filter at 20 hours or 200 miles 57 OPERATION Pre Ride Inspection AWARNING If a proper inspection is not done before each use severe injury or death could result Always inspect the vehicle before each use to ensure it s in proper operating condition Use the following checklist to verify that your vehicle is in proper working condition before each use Item Inspection Procedure 1 2 3 10 11 12 13 58 Tires Check condition and pressures Fuel and oil tanks Fill both tanks to their proper levels All brakes Check operation adjustment and fluid level includes auxiliary brake Throttle Check for free operation and closing Headlight Taillight Brakelight Check operation of all indicator lights and switches Engine stop switch Check for proper function Wheels Check for tightness of wheel nuts and axle nuts check that axle nuts are secured by cotter pins Drive chain Check condition and slack refer to drive chain adjustment section lubricate when needed Air cleaner element Check for dirt clean or replace Steering Check for free operation noting any unusual looseness in any area Loose parts Visually inspect vehicle for any damaged components or loose nuts bolts or fasteners Riding gear Wear a hel
22. at sharp angles Never turn at high speeds 64 OPERATION Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel or during freezing weather follow these precautions 1 2 3 Slow down when entering slippery areas Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward Driving with Demand 4 Drive All Wheel Drive engaged can assist in controlling the vehicle in slippery areas CAUTION Severe damage to drive train may occur if the AWD is engaged while the wheels are spinning AWARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control accident and serious injury or death Never apply the brakes during a skid Do not operate on excessively slippery surfaces Always reduce speed and use additional caution 65 OPERATION Driving Safely Driving Uphill Whenever traveling uphill follow these precautions Always travel straight uphill Avoid steep hills 25 maximum Keep both feet on the footrests Transfer your weight forward Proceed at a steady rate of speed and throttle opening 6 Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle
23. baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the terminals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into the battery AWARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN 133 MAINTENANCE AND LUBRICATION Battery Replenishing Battery Fluid Conventional Battery A poorly maintained battery will deteriorate rapidly Check the battery fluid level often The fluid level should be kept between the upper and lower level marks 1 To refill use only distilled water Tap water contains minerals that are harmful to a battery AWARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the n
24. kept clean and be of shatterproof design bearing the markings z2 1 or VESC 8 3 Gloves Off road style gloves with knuckle pads are the best for comfort and protection 4 Boots The best footwear is a pair of strong over the calf boots with heels like moto cross boots 5 Clothing Always wear long sleeves and long pants to protect arms and legs Riding pants with kneepads and a jersey with shoulder pads provide the best protection 36 CONTROLS Electrical Switches ER AWARNING Activating the override switch while the throttle is open can cause loss of control resulting in severe injury or death Do not activate the override switch while the throttle is open Override Switch 1 Reverse Speed Limiter This vehicle is equipped with a reverse speed limiter OFE RUN oF system To gain additional power while backing Pale depress the override switch NOTE The override switch also allows activation of Demand 4 Drive All Wheel Drive in reverse if the Demand 4 Drive switch is on Main Switch 2 To start the engine slide the stop switch to the center run position and turn the main key switch clockwise past the on position Release the key when the engine starts NOTE Turn off the main switch to end all electrical power to the vehicle including the cooling fan and lights AWARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury
25. must take it to a Polaris dealer authorized to repair Polaris ATVs When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate personnel at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Engine Oil 1 Mixing oil brands or using non recommended oil may cause engine damage We recommend the use of Polaris engine oil 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty 148 ACCESSOTICS ite ET AER data Steere ie 75 ACFUSEMENTS are aneso neran n 102 117 Age Restrictions 0 ccc cece eee S 7 AIP Filter oi 7 gta eceeoee a aye RS 118 119 AI Whe el Drivel ei dcc ce isang aig Gen gee a 48 49 Auxiliary Brake orasons rannin 0005 42 105 AWD aoa C nut atng chute ebeem he A 48 49 Battery ena ra ie ce TRR ELE A aon oes 134 136 Battery Conventional 133 Battery Charging S
26. owner s manual See page 69 26 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Avoid operating over large obstacles such as rocks and fallen trees when possible If unavoidable use extreme caution and always follow proper procedures as outlined in the owner s manual 4 WARNING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Skidding or sliding can cause loss of control If the tires regain traction unexpectedly the ATV could overturn HOW TO AVOID THE HAZARD On slippery surfaces such as ice travel slowly and use extra caution to reduce the chance of skidding or sliding out of control 27 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Operating the ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident or overturn HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast flowing water If its unavoidable to enter water that exceeds the recommended maximum depth see page 70 travel slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brak
27. serious injury or death Always check to be sure the parking brake is disengaged before operating Setting the Parking Brake 1 Squeeze and release the brake lever 1 two or three times then squeeze and hold Push the park brake lock 2 forward to engage the brake Release the brake lever To release the parking brake lock squeeze and release the brake lever It will return to its unlocked position N Q h Mle gs Important Safeguards The parking brake may relax if left on for a long period of time Al ways block the wheels to prevent rolling Always block the wheels on the downhill side of the ATV if leaving it parked on a hill Another option is to park the ATV in a sidehill position Never depend on the parking brake alone if the ATV is parked on a hill Always block the wheels to prevent rolling 41 CONTROLS Auxiliary Brake AWARNING Aggressively applying the rear brake when backing down a hill may cause rear tipover which could result in serious injury or death Use caution when applying the auxiliary brake Do not aggressively apply the auxiliary brake when going forward The rear wheels may skid and slide sideways causing loss of control and serious injury or death The auxiliary brake 1 is located on the inside of the right floor board and is operated by the right foot The auxiliary brake serves as a backup to the main brake system if the main system be
28. the vehicle on a level surface and engage the parking brake See page 41 2 Shift the transmission to Neutral 3 Grasp the recoil starter rope handle tightly and pull slightly until the starter mechanism engages 4 Pull the rope abruptly to start the engine CAUTION Extending the starter rope too far will cause damage to the recoil assembly Do not extend the starter rope so far that it stops If the starter rope handle is not seated properly water may enter the recoil housing and damage components Make sure the handle is fully seated on the recoil housing especially when traveling in wet areas 47 FEATURES All Wheel Drive AWD System Polaris 4 wheel drive ATVs are equipped with a unique Polaris exclusive Demand 4 Drive AWD system that s activated by a switch 1 on the right handlebar When the switch is off the ATV is in 2 wheel drive at all times When the switch is on the ATV is in Demand 4 Drive and the AWD indicator light 2 will be on When in AWD the front hubs will automatically engage any time the rear wheels lose traction When the rear wheels regain traction the front hubs will automatically disengage NOTE The override switch allows activation of Demand 4 Drive AWD in reverse if the Demand 4 Drive switch is on See page 37 There is no limit to the length of time the vehicle may remain in Demand 4 Drive Engaging Wheel Hubs The Demand 4 Drive switch may be turned on or off whil
29. toward the handlebar These brakes are self adjusting The following checks are recommended to keep the brake system in good operating condition Check more often if brakes are used heavily under normal operation 1 Always keep brake fluid at an adequate level see page 39 NOTE Under normal functioning the diaphragm extends into the reservoir as fluid level drops If the fluid level is low and the diaphragm is not extended a leak is likely and the diaphragm should be replaced Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation Use Polaris DOT 3 brake fluid see page 141 2 Check the brake system for fluid leaks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness 5 Check the security and surface condition of the disc NOTE Pads should be changed when worn to 3 64 1 cm or about the 3 64 1 cm thickness of a U S dime 104 MAINTENANCE AND LUBRICATION Adjustments Rear Brake The rear brake is a hydraulic disc brake The rear brake system is self adjusting and requires no maintenance other than periodic checks of the pads for wear Pads should be changed when worn to 3 64 1 cm which is about the thickness of a U S dime Inspect the brake disc spline and pad wear surface for excessive wear Auxiliary Brake Your vehicle
30. will result in more efficient performance and longer life for the engine Perform the following procedures carefully CAUTION Excessive heat build up during the first three hours of operation will damage close fitted engine parts Do not operate at full throttle or high speeds for extended periods during the first three hours of use Use of any oils other than those recommended by Polaris may cause serious engine damage We recommend the use of Polaris 2 cycle oil for your 2 cycle engine Lack of proper lubrication will cause serious engine damage Always fill the oil tank when refueling the ATV The first tank of fuel must be pre mixed according to the following instructions After the break in period the oil injection system will provide the necessary engine lubrication without pre mixing 1 Mix 12 8 ounces of Polaris 2 cycle oil to four gallons or 16 ounces to five gallons of gasoline in a suitable gas container Fill the fuel tank See page 43 2 Fill the oil tank with Polaris 2 cycle oil 3 Drive slowly at first Select an open area that will allow room to familiarize yourself with vehicle operation and handling 4 Vary the throttle positions 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 58 After the first tank of pre mixed fuel has been used verify that the oil level in the oil tank has dropped indicating that the oil pump is functioni
31. 0 seconds Clutch seals should be inspected for damage if repeated leaking occurs Clutch malfunction Contact your Polaris dealer for inspection of clutch com ponents Poor engine performance Check for fouled plugs or foreign material in gas tank fuel lines or carburetor Contact your dealer for service 142 TROUBLESHOOTING Contact your Polaris dealer for service if you re unable to identify solutions using the following charts Engine Doesn t Turn Over Possible Cause Solution Tripped circuit breaker Reset the breaker Low battery voltage Recharge battery to 12 5 VDC Loose solenoid connections Check all connections and tighten Engine Turns Over Fails to Start Possible Cause Solution Turn fuel valve to reserve refuel Mechanical failure Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs 143 TROUBLESHOOTING Engine Backfires Possible Cause Solution Weak spark from spark plugs Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Mechanical failure Engine Runs Irregularly Stalls or Misfires Possible Weak Spark Cause Solution Other mechanical failure Possible Lean Fuel Mixture Cause Solution Possible Rich Fuel Mixture Cause Solution
32. 1 Stop and lock the parking brake while keeping body weight uphill 2 Leave transmission in forward and shut off the engine 3 Dismount on the uphill side of the vehicle or on the left if the vehicle is pointing straight uphill 4 Staying uphill of the vehicle turn the handlebars full left 5 While holding the brake lever release the parking brake lock and slowly allow the vehicle to roll around to your right until it s pointing across the hill or slightly downward 6 Lock the parking brake and remount the vehicle from the uphill side keeping body weight uphill 7 Restart the engine with the transmission still in forward 8 Release the parking brake and proceed slowly controlling speed with the brake until the vehicle is on more level ground 69 OPERATION Driving Safely Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests 1 Follow these procedures when 2 oP na operating through water 1 Determine water ag depths and current before crossing 2 Choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles if possible 4 After crossing dry the brakes by applying light pressure to the lever until braking action is normal After running the vehicle in water it s critical to have it serviced as outlined in the maintenance chart See page 75 The following areas nee
33. 3 Purge carbon from the system by momentarily revving the engine several times 4 If carbon is expelled cover the exhaust outlet and rap on the pipe around the cleanout plug while revving the engine several more times 5 If particles are still suspected to be in the muffler back the vehicle onto an incline so the rear of the vehicle is one foot higher than the front Set the parking brake and block the wheels Make sure the vehicle is in neutral and repeat steps 3 and 4 6 If particles are still suspected to be in the muffler drive the vehicle onto the incline so the front of the vehicle is one foot higher than the rear Set the parking brake and block the wheels Make sure the vehicle is in neutral and repeat steps 3 and 4 7 Repeat steps 3 through 6 until no more particles are expelled when the engine is revved 8 Stop the engine and allow the arrestor to cool Reinstall the arrestor plug 129 MAINTENANCE AND LUBRICATION Recoil Housing To prevent possible engine damage always drain the recoil housing after operating the ATV in very wet conditions This should also be done before storing the ATV Water will enter the recoil housing if the starter handle is disengaged from the rope guide when under water NOTE On the Trail Blazer 250 the recoil handle must be behind the heat shield for it to seal properly The drain screw is located at the bottom of the recoil housing Use a wrench to remove the screw Be sure to re
34. 6 E Electrical Switthes s yee ug Goatees een Ws as 37 Engaging Wheel Hubs 48 Engine Cooling System 99 101 Engine Fogging 2 cece eects nee nee 139 Engine Oil Check i ss eencnis oserei aiana 98 Equipment Modifications 11 INDEX FEATURES 645 0946 00 034940000 9 49804K 48 55 Filter Systems gt 35 63 0035 26s deo eebs 00 118 119 Front Brake 3 ojc0 5 4 sok ees ere aA 104 Front Gearcase Oil Change 95 Front Gearcase Oil Check 4 95 Front Wheel Hub Tightening 114 Buch Pilter ei gees an boda eid energies Geeta E 43 Fuel Safety os chose wenn sews em eae weens 44 Fuel Stabilizetios s lt os pe0 6 0 dane dyn aA 138 Fuel Tari ke rei snra decigtrs ayn eng anya esend en 555 43 BUCU VAL V6 eeina Oso a toa nee ce Bing wien 43 G Gear Selector hreig a e saad a kes 46 Gearcase Oil Fill Chart 0 91 H Handlebars cars disc os hoes Sa os 6 108 Hauling Cargo 0 0 ta riea t ia iai 61 62 Headlight Adjustment Trail Blazer 121 Headlight Housing Replacement Gen IV 124 Headlight Lamp Replacement Gen IV 122 Headlight Lamp Replacement Scrambler 120 Headlight Lamp Replacement Trail Blazer 121 FIEIME reo nc shea hs CAF F Sere Cah ESS Oa 36 High Beam Adjustment Gen IV 123 High Beam Adjustment Scrambler 120 High Rangess car Jee Seat aose bak EAE oa 131 Hour Mete
35. Front Drive Grease Locate grease fitting and grease with Every 3 Axle U Joint grease gun months or 50 AWD Models hours 8 Ball Joint px Locate fitting on back side of struts Every 3 Grease and grease with grease gun months or 50 hours 9 Counter Polaris Check level on dipstick and add oil as Check Balance Housing Premium necessary Change annually monthly and 400 Synthetic change 4 cycle or annually SAE 10 30 10 Rear Axle px Locate fittings and grease Every 3 Bearing Grease months or 50 hours 11 Swing Arm px Locate fittings on swing arm and Monthly or at Bushings Grease grease with grease gun 20 hours 12 Upper Con BXA Locate fittings and grease Semi annually trol Arms Grease 13 Lower Con BXA Locate fittings and grease Semi annually trol Arms Grease 14 Rear Wheel BXA Locate fitting and grease Semi annually Hub Bearing Car Grease rier 15 Rear Anti gt Locate fitting and grease Semi annually Roll Bar Grease p gt More often under severe use such as wet or dusty conditions Polaris Premium All Season Grease or grease conforming to NLGI No 2 such as Conoco Superlube M or Mobilegrease Special Use Polaris Premium U Joint Lube every 500 miles before long periods of storage or after pressure washing or submerging A When suspension action becomes stiff or after washing 82 MAINTENANCE AND LUBRICATION Lubrication Recommendations 6 4 O clock position 83
36. ION CONTROL SYSTEM REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED U S Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW INCLUDE BUT ARE NOT LIMITED TO THE FOLLOWING 1 Removal or alteration or the puncturing of the muffler or any engine component which conducts removal of engine exhaust gases 2 Removal or alteration or the puncturing of any part of the engine air induction system 3 Replacement of any vehicle parts with parts not in compliance with federal regulations 4 Lack of proper maintenance 4 CAUTION Exhaust system components are very hot during and after use of the vehicle Hot components can cause serious burns and can cause a fire to ignite Do not touch hot exhaust system components Use caution when traveling through tall grass especially dry grass USFS Approved Spark Arrestor Most Polaris ATVs have mufflers that were tested and approved in accordance with the USFS Forest Service Standard 5100 1A
37. LS Fuel Safety 44 AWARNING Gasoline is highly flammable and explosive under certain conditions e Always exercise extreme caution whenever handling gasoline e Always refuel with the engine stopped and outdoors or ina well ventilated area e Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored e Do not overfill the tank Do not fill the tank neck e f gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing e Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of con sciousness or death in a short time e Turn the fuel valve off whenever the ATV is stored or parked AWARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas CONTROLS Oil Injection Tank 2 Cycle Models CAUTION Mixing brands or using a non recommended oil may cause serious engine damage We recommend the use of Polaris Premium Synthetic 2 cycle oil for your 2 cycle Polaris ATV Never substitute or mix oil brands To avoid serious engine damage always top off the oil level when refueling Models with 2 cycle engines have oil injection The oil injection tank filler cap 1 is located on the front of the vehicle Tank capacity is t
38. PLETE AN ATV SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE ATV No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your ATV is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage 146 WARRANTY WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any ATV that has been altered structurally modified neglected improperly maintained used for racing or used for purposes other than for which it was manufactured or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or
39. Place the transmission in gear with the parking brake applied 3 Adjust the carburetor idle screw 1 either in or out until the desired idle RPM is reached Turning the screw in clockwise will raise RPM Turning the screw out counterclockwise will lower RPM The following variations apply to air screw 2 adjustment for 2 cycle engines e For improving cold weather start and reducing audible detonation noise the air screw can be closed from 1 2 to 1 turn by turning the screw clockwise During hot weather and or high altitude operation the air screw can be adjusted for smoother operation by turning the screw counter clockwise for approximately 2 turns 109 MAINTENANCE AND LUBRICATION Adjustments Carburetor 4 Cycle Engines If the engine idle speed is not satisfactory and all other conditions are favorable the carburetor can be adjusted 1 Warm up the engine by running the vehicle for approximately five minutes 2 Place the transmission in gear with the parking brake applied 3 Adjust the carburetor idle screw 1 either in or out until the desired idle RPM is reached Turning the screw in clockwise will raise RPM Turning the screw out counterclockwise will lower RPM Throttle Cable Freeplay Throttle cable freeplay is adjusted at the handlebar 1 Slide the boots 1 off the inline cable adjuster sleeve 2 Loosen the adjuster locknut 3 2 Turn the adjuster until 1 16 to 1 8 freep
40. Polaris Professional Series Workmobiles e Utility Task Vehicles UTVs e Personal Task Vehicles PTVs e All Surface Loaders ASLs We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today Many years of experience have gone into the engineering design and development of your Polaris vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your service needs during and after the warranty period We also take great pride in our Parts Apparel and Accessories PAA products available through our online store at www purepolaris com Have your accessories and clothing delivered right to your door Polaris Polaris The Way Out and Workmobiles are registered trademarks of Polaris Industries Inc TABLE OF CONTENTS WELCOME hice maca sind hye whould ats 3 TABLE OF CONTENTS 0 00 000 5 VEHICLE IDENTIFICATION NUMBERS 6 SAFETY heated ars eu liee tad gat
41. T 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 Rear 180 Lbs 7170021 On models with racks A WARNING Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death 7078689 NO STEP ATTENTION eSpecific carburetor jetting eOperation of this and adjustments are vehicle without the required depending on temperature filter element will severely and altitude See your Owner s Manual damage the engine Factory setting Clean air filter often more frequent cleaning required 40 to 80 F at 0 3000 feet 5 to 27 in dusty conditions C at 0 900 meters Under Seat 34 7079901 SAFETY Safety Decals and Locations Chain Freeplay Is Important Adjust Freeplay to 3 16 3 8 OVERRIDE DO NOT Overtension See SWITCH Owner s Manual 4 WARNING Pushing reverse override button may cause sudden in creases in pow er and traction if too much throttle is ap Reverse Speed is Torque Nut on Eccentric Bolts To 30 Ft Lbs For models limited without a hitch ahs To 60 Ft Lbs For models with Reverse override is a hitch r controlled by the EES plied L
42. TH DRUGS ePARKING BRAKE may relax when used for more than HELMET AND ROADS OR ALCOHOL 5 minutes When parking on grades leave shift in for Nee vag 7079085 NEVER operate without proper training or instruction Non drum shift models hee i at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle AWAR N N G with a passenger passengers affect balance and steering and increase risk of losing control Never operate this vehicle on HILLS steeper than 25 degrees 25 ALWAYS To prevent flipover on hilly terrain when going up or down use use proper riding techniques to avoid vehicle throttle and brakes gradually overturns on hills and rough terrain and in turns eREVERSE operation can be dangerous even at low avoid paved surfaces pavement may seriously speeds Steering becomes difficult To prevent flipover affect handling and control avoid sudden braking or sharp turns ee F LOCATE AND READ OWNER S MANUAL eUse OVERRIDE for reverse speed limiter with caution To prevent loss of control never activate override button Teed eal einiecin z VARNING S with open throttle A POLARIS DEALER FOR A REPLACEMENT eWhen this ATV is not in operation or unattended place 1997 2000 7079083 shift in park position 7171383 Drum shift models AWARNING This ATV may exceed the perfor mance of other ATVs you may have ridden in the past This category S Sport
43. V with the tires 1 2 off the ground Be sure the storage area is well ventilated and cover the machine with a genuine Polaris ATV cover NOTE Do not use plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation Transporting the ATV Follow these procedures when transporting the vehicle 1 Turn off the engine and remove the key to prevent loss during transporting 2 Turn the fuel valve off 3 Be sure the fuel cap oil cap and seat are installed correctly 4 Always tie the frame of the ATV to the transporting unit securely using suitable straps or rope 5 Always place the transmission in gear and lock the parking brake 140 POLARIS RECOMMENDED PRODUCTS Part No Description 287079 2571098 2871721 2871281 Premium 4 Synthetic OW 40 Engine Oil 4 Cycle qt 2873602 2571653 2871654 ZANE 2871322 2871423 2871480 2571515 2871557 2871329 2871323 60 40 Coolant gal 2871534 60 40 Coolant qt 141 TROUBLESHOOTING Drive Belt and Cover Problems Driving the ATV onto a Shift transmission to low range during loading of the ATV pickup or tall trailer in to prevent belt burning high range Starting out going up a When starting out on an incline use low range or dis steep incline mount the ATV after first applying the park brake and perform the K turn as described on page 69 Driving at low RPM or Drive at a higher spee
44. VE DYING prii n eRe a yates oes 132 PVT System 1 cece eee eee ee 131 132 R Radiator Coolant Level 100 Rear Braken to 924109 egat ee an 105 Rear Drive Chain Slack 116 117 Rear Gearcase Oil Change 96 Rear Gearcase Oil Check 96 Rear Sting oie rinaos iann eee Naa i es 107 Recoil Housing o n eds ls fea dele Se 130 Recoil Starter neniarn anian aon Paes oes 47 Rider Information Center 52 55 S Safe Riding Geary 164 6294 Gann Gavia nsses 36 SAFETY sy cued rots oss SRE eee 7 36 Safety Decals and Locations 32 35 Safety Training syisa se ian piana GERE T 7 Side Panel Removal Gen IV 111 Sid billing ae veya merae ee Ta ISS 67 Spark Arrestor os 2ec2e ev daeeed cea 74 128 129 Spark Plug Removal and Replacement 126 Spark Plug Sere see 58 Ges EMSs SERA E SERS 126 Starting a Cold Engine 59 150 Starting a Warm Engine 60 Starting the Engine 0 lt ayd gece ds dees 59 60 Steering Assembly coy ca deca decade Gaddond 107 Bip SWUCH cern edad iuar da ded wep cece 37 Storage TIPS fend nee date parpin ieas 138 140 TABLE OF CONTENTS 000005 5 Taillight Brakelight Lamp Replacement 125 Throttle Cable Freeplay 0 110 Throttle Levert onadan oiana noA ghee 38 Tite Tr ad Depths ood denen cadet eee ceed 114 Toe Alignment ios dee gamed AKRA 106
45. WAYS e Avoid paved surfaces which may adversely affect handling and control e Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills and rough terrain and in turns e Wear eye protection helmet and protective apparel READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS gt POLARIS The Way Out Part No 9917492 Rev 05 PRINTED IN THE USA
46. activate the override switch and the Demand 4 Drive switch See page 37 AWARNING Operating with only one front hub engaged could result in loss of control accident and severe injury or death When hub engagement symptoms are present use the disengaging procedure before proceeding 49 FEATURES Indicator Lights The configuration of the indicator lights differs with individual models Not every model is equipped with all of the lights and the lights on some models appear in the speedometer The information in your owner s manual supplement and on this page will help you identify the lights and their function With the engine running verify the function of all indicator lights each time the ATV is used NOTE The taillight is on whenever the main switch key is on Turn the key off to prevent battery drain 4 1 L Transmission Neutral Indicator green Transmission Low Gear Indicator blue grey Transmission Reverse Indicator yellow Oil Warning red On 2 cycle models this light indicates a low oil level 5 High Temp Warning red This light will display if the engine overheats 6 All Wheel Drive Indicator red See page 48 for more information about AWD 7 High Beam Indicator blue AUNA 50 FEATURES Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel The instrument cluster measures distance in miles as well as hours of oper
47. age If the machine is used in wet conditions check the oil more frequently NOTE If the oil has a milky appearance it should be changed as soon as possible Failure to properly maintain the counter balance lubrication can result in premature wear or possible failure of the counter balance components Always use SAE 10W30 oil 1 Remove the seat and remove the dipstick 1 2 Read the oil level If necessary add SAE 10W30 oil with a transmission fluid funnel until the oil reaches the recommended level on the dipstick 2 NOTE If overfilled the 2 excess oil will be expelled through SS the vent hose 3 Reinstall the dipstick and reinstall the seat Counterbalance Oil Change 400 2 Cycle Engines Drain Locations A Counter Balance Drain B Crankcase Drain C Recoil Drain D Starter Pinion Drain 1 Remove the skid plate and remove the counter balance drain plug A Catch used oil and discard of properly C 2 Clean and reinstall the drain plug 3 Add 10W30 oil to the full mark on the dipstick Capacity after draining is approximately 2 3 2 5 oz 70 75 cc 4 Reinstall the dipstick and check for leaks 97 MAINTENANCE AND LUBRICATION Lubrication Recommendations Engine Oil Check The oil tank is located either on the left side of the vehicle external tank models 1 or on the engine 2 1 Position the machine on a level surface 2 Start the engine and let it idle for 20 30 sec
48. alance and control the ATV which could cause an accident and injury to the operator and or passenger HOW TO AVOID THE HAZARD Never carry a passenger The purpose of the long seat is to allow the operator to shift position as needed during operation It is not intended for carrying passengers 13 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Operating an ATV on paved surfaces including sidewalks paths parking lots and driveways WHAT CAN HAPPEN ATV tires are designed for off road use Operating on paved surfaces may seriously affect the handling and control of the ATV and could result in loss of control accident and or injury HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement If it s unavoidable travel slowly and avoid sudden turns or stops 14 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Operating this ATV on public streets roads or highways WHAT CAN HAPPEN The ATV could collide with another vehicle HOW TO AVOID THE HAZARD Never operate the ATV on any public street road or highway including dirt and gravel roads In many states it s illegal to operate ATVs on public streets roads and highways 15 SAFETY Operator Safety 16 4 WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet eye protection and protective clothing WHAT CAN HAPPEN Operating an ATV without an approved helmet increases the risk of a severe hea
49. aler perform these operations Maintenance Chart Key p Perform these operations more often under severe use such as in dirty or wet conditions to purge water or dirt contamination from grease fittings and other critical components Emission Control System Service California 4 Cycle NOTE Some 4 Cycle models may have an additional California only emissions warranty Please refer to your owner s manual supplement for model specific information m Dealer service item 75 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Hours of operation are based on a 10 mph average If service is due at 20 hours the equivalent odometer reading would be 200 miles Perform all services at whichever reading is reached first AWARNING Improperly performing the procedures marked with a m could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services Hours Frequency Miles Tres Prerige a S Prefide Preride Inspect Frame nuts bolts Pre Ride Pre Ride Inspect fasteners E Oil level 2 Cycle Check when refueling p gt Air filter Pre Ride Pre Ride Inspect clean Pre cleaner P Coolant level Replace coolant every two years Fuel and oil tanks Fill to proper levels Engine stop switch Check operation Air box sediment Pre Ride Pre Ride Drain deposits whenever tube visible Headlamp Pre Ride Pre Ride Check operation daily
50. ar terrain Always be alert to changing terrain conditions 20 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough slippery or loose terrain WHAT CAN HAPPEN Operating on excessively rough slippery or loose terrain could cause loss of traction or loss of control which could result in an accident or overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you ve learned and practiced the skills necessary to control the ATV on such terrain Always use extra caution on rough slippery or loose terrain 21 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner s manual Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speed 4 WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle may overturn HOW TO AVOID THE HAZARD Never operate on hills too steep for the ATV or for your abilities Never operate the ATV on hills steeper than 25 Practice on smaller hills before attempting large hills 22 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Climbing hills improperly
51. ards while climbing a hill To avoid stalling maintain a steady speed when climbing a hill If you stall or roll backwards follow the special pro cedure for braking described in this manual Always dismount on the uphill side or to either side if the ATV is pointed straight uphill Turn the ATV around and remount following the procedure de scribed in this manual Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as rocks or fallen trees Always follow proper procedures when operating over obstacles as described in this manual Always be careful of skidding or sliding On slippery surfaces like ice travel slowly and use extra caution to reduce the chance of skid ding or sliding out of control Avoid operating the ATV through deep or fast flowing water If it s unavoidable travel slowly balance your weight carefully avoid sud den movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes 10 SAFETY Operator Safety e Wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them lightly several times to allow friction to dry out the pads e Always check for obstacles or people behind the ATV before operat ing in reverse When it s safe to proceed in reverse move slowly and avoid turning at sharp angles e Always use the size and type of tires spe
52. as described in this manu al Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speeds SAFETY Operator Safety Always have the ATV inspected by an authorized Polaris dealer if it s been involved in an accident Never operate on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills Check the ter rain carefully before ascend a hill Never climb hills with excessive ly slippery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes Never go over the top of a hill at high speed Always follow proper procedures for going downhill and for braking on hills Check the terrain carefully before you start down a hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when pos sible Always follow proper procedures for crossing the side of a hill Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV Never attempt to turn the ATV around on any hill until you ve mastered on level ground the turn ing technique outlined in this manual Avoid crossing the side of a steep hill when possible Always use proper procedures if you stall or roll backw
53. ation It also includes a reverse speed limiter function that limits the ATV s speed to approximately 7 9 mph Refer to page 37 for additional information 1 Rider Information Center Speedometer needle in addition to depicting vehicle speed this needle will flash to signal a fault condition 3 Speedometer CAUTION Washing the ATV with a high pressure washer may cause water to enter the instrument cluster and cause damage to the electronic components Wash the ATV by hand or with a garden hose using mild soap Do not use alcohol to clean the instrument cluster Immediately clean off any gasoline that splashes on the instrument cluster 51 FEATURES Instrument Cluster Rider Information Center The rider information center is located in the lower portion of the instrument cluster 1 Gear Indicator As the shift lever is moved this will indicate the gear the machine is in H High Range L Low Range N Neutral R Reverse P Park E or blank Error The error message usually means the gear selector is in between gears It can however also indicate that the transmission switch needs repair 2 High Engine Coolant Temperature Do not continue to operate the ATV is this warning appears or serious engine damage could result 3 Hour Meter 4 Service Interval Miscellaneous Service Warnings 5 Low Battery and Over Voltage This warning usually indicates that the ATV is being operated at an RPM
54. cified for your ATV and always maintain proper tire pressure e Never modify an ATV through improper installation or use of acces sories e Never exceed the stated load capacity for your ATV Cargo must be properly distributed and securely attached Reduce speed and follow the instructions in this manual for carrying cargo or towing Allow a greater distance for braking e Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting FOR MORE INFORMATION ABOUT ATV SAFETY call the Con sumer Product Safety Commission at 1 800 638 2772 or call Polaris at 1 800 342 3764 Equipment Modifications We are concerned for the safety of our customers and for the general public Therefore we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury The warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power NOTE The addition of certain accessories including but not limited to mowers blades tires sprayers or large racks may change the handling characteristics of the vehicle Use only Polaris appr
55. comes inoperative If the rear wheels slide while using the auxiliary brake reduce brake pedal pressure to brake the rear wheels without skidding Check the brake fluid level frequently for the auxiliary brake system The reservoir is located under the seat or near the foot brake Maintain the fluid level between the maximum and minimum marks 42 CONTROLS Choke The choke assists in starting a cold engine Refer to the engine starting procedure on page 59 for correct choke and throttle settings during starting Fuel Valve The fuel valve 1 is located on the left side of RES the vehicle either below the fender or on the side panel It has three positions OFF OFF For vehicle storage and when transporting ON For normal operation RES For reserve supply if main supply is exhausted NOTE There s about a 7 to 10 mile 11 2 to 16 km range on reserve gas Always refill the gas tank as soon as possible after using the reserve supply Always return valve to on position after refueling Fuel Tank The fuel tank filler cap 2 is located directly below the handlebar Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Refer to your owner s manual supplement for tank capacity 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 43 CONTRO
56. ct all cables and lubricate with Polaris Cable Lubricant Follow lubrication guidelines in the maintenance section of the service or owner s manual to completely grease and lubricate the entire vehicle with Polaris Premium All Season Grease Apply Polaris O Ring Chain Lube to the drive chain s 139 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips Battery Storage Conventional Battery Remove the battery and add distilled water to the proper level Do not use tap water which may contain minerals that reduce battery life Apply Polaris di electric grease to the terminal bolts and terminals Charge the battery at 1 4 amps or less until the specific gravity of each cell is 1 265 or greater While the battery is in storage check the fluid level once a month Sealed Battery Remove the battery and ensure that it s fully charged See page 135 for instructions Both battery types should be stored in a cool dry place Battery charge can be maintained easily by using Polaris Battery Tender charger PN 2871076 or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point Engine Anti Freeze Test engine coolant strength and change if necessary Coolant should be replaced every two years Storage Area Covers Set the tire pressure and safely support the AT
57. d injury or death in the event of an accident Operating without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Operating the ATV after consuming alcohol or drugs WHAT CAN HAPPEN Consumption of alcohol and or drugs could seriously affect operator judgment Reaction time may be slower and operator balance and perception could be affected Consuming alcohol and or drugs before or while operating an ATV could result in an accident causing severe injury or death HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while operating an ATV 4 WARNING POTENTIAL HAZARD Operating the ATV at excessive speeds WHAT CAN HAPPEN Excessive speed increases the operator s chance of losing control of the ATV which can result in an accident HOW TO AVOID THE HAZARD Always operate the ATV at a speed that s proper for the terrain visibility and operating conditions and your experience 17 SAFETY Operator Safety 18 4 WARNING POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Attempting stunts increases the chance of an accident including an overturn HOW
58. d or use low range more frequently low ground speed at The use of low range is highly recommended for cooler approximately 3 7 MPH PVT operating temperatures and longer component life Insufficient warm up of Warm the engine at least 5 minutes With the transmission ATVs exposed to low am in neutral advance the throttle to about 1 8 throttle in bient temperatures short bursts 5 to 7 times The belt will become more flex ible and prevent belt burning Slow and easy clutch en Use the throttle quickly and effectively for efficient enga gagement gement Towing pushing at low Use low range only RPM low ground speed Utility use plowing snow Use low range only dirt etc Stuck in mud or snow Shift the transmission to low range and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large ob Shift the transmission to low range and carefully use fast jects from a stopped posi brief aggressive throttle application to engage clutch tion WARNING Excessive throttle may cause loss of control and vehicle overturn Belt slippage from water Shift the transmission to neutral Using the throttle vary or snow ingestion into the the engine RPM from idle to full throttle Repeat several PVT system times as required During this procedure the throttle should not be held at the full position for more than 1
59. d periods 14 Reinstall the drain plug NOTE The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches 15 Remove the dipstick 2 and add the amount of oil indicated in your owner s manual supplement Reinstall the dipstick NOTE If the sump is not drained add about 1 3 4 quarts initially 16 Place the gear selector in neutral and set the parking brake 17 Start the engine and let it idle for one to two minutes Stop the engine and inspect for leaks 18 Re check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the N dipstick 19 Dispose of used filter and oil properly 88 MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change Magnum 330 2x4 Magnum 330 4x4 Trail Boss 1 Position the vehicle on a level surface 1 2 Clean the area around the drain plug 1 3 Run the engine for two to three minutes until warm Stop the engine 4 CAUTION Contact with hot oil may result in serious burns Do not allow hot oil to come into contact with skin 4 Place a drain pan beneath the engine crankcase and remove the drain plug 5 Allow the oil to drain completely 6 Install a new sealing washer on the drain plug NOTE The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches 7 Reinstall the drain
60. d special attention engine oil transmission oil front and rear gearcases and all grease fittings 4 CAUTION Major engine damage can result if the vehicle is not thoroughly inspected after operation in water Perform the services outlined in the maintenance chart If your vehicle becomes immersed or is operated in water that exceeds the footrest level take it to your dealer for service before starting the engine NOTE Avoid operating the vehicle through deep or fast flowing water If you cannot avoid water that exceeds the recommended maximum depth go slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes If your vehicle becomes immersed and it s impossible to take it to a dealer before starting it follow the steps described on page 127 Have the vehicle serviced by your dealer at the first opportunity 70 OPERATION Driving Safely Driving Over Obstacles adh hn Pa a hi TOA Za Wh Ges ati Be alert Look ahead and learn to read the terrain you re traveling on Be constantly alert for hazards such as logs rocks and low hanging branches AWARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle Not all obstacles are immediately visible Travel with caution in unfamiliar terrain 71 O PERATION Driving Safely Driving in Re
61. dd 2 3 tablespoons of Premium 4 Synthetic 0W40 engine oil To access the plug hole use a section of clear 1 4 hose and a small plastic squeeze bottle filled with the pre measured amount of oil Note Do this carefully If you miss the plug hole oil will drain from the spark plug cavity into the hole at the front of the cylinder head and appear to be an oil leak Install the spark plug and pull the engine over slowly with the recoil starter Oil will be forced in and around the piston rings and ring lands coating the cylinder with a protective film of fresh oil If you choose not to use Polaris Fogging Oil perform the following procedure 1 Support the front end of the machine so the engine is level or tilted slightly rearward 2 Remove the spark plug s Rotate the piston to BDC and pour approximately two ounces of Polaris recommended oil into the cylinder NOTE Be sure to use 2 cycle oil in 2 cycle engines and 4 cycle oil in 4 cycle engines 3 Apply dielectric grease to the inside of the spark plug cap and install the cap onto the plug 4 Turn the engine over several times to ensure coverage of piston rings cylinder walls and crankshaft bearings 5 Treat the fuel system with Polaris Carbon Clean 6 If Polaris fuel system additive is not used fuel tank fuel lines and carburetor should be completely drained of gasoline To eliminate any fuel remaining in the carburetor run the engine until it stops Lubricate Inspe
62. e Mins eae ae 7 CONTROLS oee ee a8 pcr lec oad of Se wee we 37 FEATURES tatyecri sexe S N EO tenes 48 OPERATION Soie baei toO EEE 56 NOISE EMISSION CONTROL SYSTEM REGULATION 4 74 MAINTENANCE AND LUBRICATION 75 POLARIS RECOMMENDED PRODUCTS 141 TROUBLESHOOTING 0 005 142 WARRANTY estrous eG facto A T aucun 146 INDEX ard est rte ih artes dean nel aA a wd bata ta aes 149 NOTE Illustrations used in this manual are for general representation only Your model may differ VEHICLE IDENTIFICATION NUMBERS The vehicle frame vehicle identification number VIN 1 and engine serial number 2 are important for model identification when registering your vehicle when obtaining insurance and when ordering replacement parts If your vehicle is stolen these numbers are essential to the recovery and identification of your vehicle Remove the spare key and store it in a safe place Your key can be duplicated only by mating a Polaris key blank with one of your existing keys If both keys are lost the ignition switch must be replaced See your Polaris dealer NOTE Record your vehicle s ID numbers and key number 3 in the spaces provided Frame VIN Vehicle Model Number Engine Serial Number right front side of engine crankcase Key Number Dealer Imprint SAFETY Operator Safety AWARNING Failure to follow the warnings contained in this manual can result in severe in
63. e clear NOTE When checking the fluid level the ATV must be on level ground with the handlebars straight If the fluid level is low add DOT 3 brake fluid only See page 141 for the part numbers of Polaris recommended products j SCM i HEH AWARNING After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of accident or severe injury 39 CONTROLS Brake Lever The front and rear brakes are applied by squeezing the brake lever 1 toward the handlebar The front and rear brakes are hydraulically activated disc type brakes that are activated by only one lever Always test brake lever travel and master cylinder fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before riding Contact your dealer for proper diagnosis and repairs AWARNING Operating the ATV with a spongy brake lever can result in loss of braking which could cause an accident Never operate the ATV with a spongy feeling brake lever 40 CONTROLS Parking Brake AWARNING Operating the ATV while the parking brake is engaged could result in an accident and
64. e replacement bulb into headlight housing and rotate clockwise firmly NOTE The bulb must be positioned so the harness installs into the lamp at the bottom 4 Reinstall the connector to the back of the headlight High Beam Adjustment Scrambler The headlight beam can be adjusted vertically 1 Position the ATV on a level surface with the headlight approximately 25 ft 7 6 m from a flat wall 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 3 Start the engine and turn the headlight switch to high beam 4 Observe the headlight aim on the wall The most intense part of the headlight beam should be aimed 2 5 1 cm below the mark placed on the wall NOTE Include rider weight on the seat when measuring 5 Loosen the pivot bolt and adjust the beam to the desired position 6 Tighten the bolt and torque to 60 in Ibs 120 MAINTENANCE AND LUBRICATION Lights Headlight Lamp Replacement Trail Blazer 1 2 3 4 5 6 Remove the front cover and unplug the light harness Remove the rubber cap from the back of the headlight to reveal the retention screw Remove the small phillips head screw and carefully remove the bulb from the housing Apply dielectric grease to the light bulb socket before installing the new bulb Insert the new bulb into the housing and reinstall the retention screw Reinstall the rubber cap Reconnect the light
65. e the vehicle is moving Initially the vehicle s electronic system will not enable the AWD until the engine RPM is below 3100 Once enabled the AWD remains enabled until the AWD switch is turned off If the switch is turned off while the front hubs are moving the hubs will not disengage until the rear wheels regain traction NOTE Select AWD models do not have an AWD switch These models are continuously in AWD Engage the Demand 4 Drive switch before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to Demand 4 Drive CAUTION Switching to AWD while the rear wheels are spinning may cause severe drive shaft and hub damage Always switch to AWD while the rear wheels have traction or are at rest 48 FEATURES All Wheel Drive AWD System Disengaging Wheel Hubs Although the hubs normally disengage when operating in reverse one or both hubs may occasionally remain engaged If the handlebars pull to one side it s likely that one front hub is engaged If both hubs are engaged steering effort increases but remains balanced from left to right and vehicle speed is somewhat restricted Disengage the hubs by stopping shifting to reverse and backing for a short distance Then proceed in forward again NOTE If the hubs remain engaged after following this procedure return the ATV to your dealer for service To continue using AWD in reverse
66. ealed Battery 135 136 Battery Fluid Conventional 134 Battery Installation 00 135 Battery Removal 000 00005 134 Battery Storage pave tee vee nes 135 140 Belt Life res re ear ra a ae ean 46 Brake Leyer r miann anipatie nE 40 Brakes s i ake aa a an E E A 39 Break in Period 2 Cycle 54 56 Break in Period 4 Cycle 5 57 Break In Period 32s ei eee vevguanay 56 57 Breather Filter Hose 0006 119 C Camber and Casters n n nannan 107 Carburetot s ops Tons SERA Ona eee leases CRON G56 lg EG IC E RATA Cleaning and Storage Cleaning the ATV Cold Weather Operation 4 Cycle 60 CONTROLS sine id os o4 eo cat eed eGind 37 47 Coolant Level posia sori anri hohe oop Sea ER 99 Counter Balance Oil Check 400 Engines 97 Counterbalance Oil Change 400 Engines 97 Cylinder Head Cylinder Base Fastener 115 D Diagnostic Mode 0 0 eee eee 55 Disengaging Wheel Hubs 49 Drive Chait entans s eS KE SERS URUK OSS Swed 115 Driving Downhill 0000 68 Driving in Reverse sorry n aera a 00 000 72 Driving on Slippery Surfaces 65 Driving Over Obstacles 00 71 Driving Procedures 00 00 000 63 Driving Safely serra tc rea vid eee da non oe 63 73 Driving Through Water 70 Driving Uphill 253 5 6a3 86508 rah eoss cakes 6
67. eating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures See your dealer as outlined in the owner s manual This PVT system is intended for use on Polaris products only Do not install it in any other product Always make sure the PVT housing is securely in place during operation PVT Drying There may be some instances when water is accidently ingested into the PVT system Use the following instructions to dry it out before operating 1 Remove the drain plug and allow the water to drain Replace the drain plug 2 Start the engine and shift the transmission into neutral Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds 3 Allow the engine RPM to settle to idle speed then shift the transmission to the lowest available range 4 Test for belt slippage If the belt slips repeat the process Take the vehicle to your dealer for service as soon as possible 132 MAINTENANCE AND LUBRICATION Battery Conventional Keep the battery terminals and connections free of corrosion If cleaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon
68. egative black cable last Battery Removal 1 Disconnect the hold down strap holding the battery in position and remove battery cover Remove the battery vent tube from the battery Disconnect the black negative battery cable first Disconnect the red positive battery cable next Lift the battery out of the ATV Be careful not to tip a conventional battery sideways which could spill electrolyte 4 CAUTION If electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle iB Us be 134 MAINTENANCE AND LUBRICATION Battery Battery Installation 1 Set the battery in the battery holder 2 With conventional batteries install the battery vent tube Sealed batteries do not have a vent tube NOTE The vent tube must be free of obstructions and securely installed If not battery gases could accumulate and cause an explosion The tube should be routed away from the frame and body to prevent corrosion Avoid skin contact with electrolyte which can cause severe burns First connect and tighten the red positive cable Second connect and tighten the black negative cable Reinstall the battery cover and attach the hold down strap Nn ew Verify that cables are properly routed NOTE When installing a new battery make sure it s fully charged prior to its initial use Using a new battery that has not been fully charged can damage the batt
69. ery and result in a shorter life It can also hinder vehicle performance Battery Storage When the vehicle is placed in storage for three months or more the battery should be removed stored out of the sun in a cool dry place and tested monthly Before reusing take the battery to your dealer for testing and recharging Power plug leads may need to be bent down so that the battery cover can be installed Battery Charging Sealed Battery The following battery charging instructions apply only to the installation of a YUASA activated sealed battery Read all instructions before proceeding with the installation of this battery The YUASA activated sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Do not ever pry the sealing strip off or add any other fluid to this battery The single most important thing to maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to meas

JVC KS-F350R Cassette Player User Manual

Contents