1
WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our world-
wide family of Polaris owners. We proudly produce an exciting line of
utility and recreational products.
• Snowmobiles
• All-terrain vehicles (ATVs)
• Quadricycles
• RANGER utility vehicles
• Victory motorcycles
Always follow the instructions and recommendations in this manual.
The manual contains instructions for minor maintenance, but informa-
tion about major repairs is outlined in the Polaris Service Manual and
should be performed only by a Factory Certified Master Service Dealer
(MSD) Technician. Please see your dealer for all of your service needs
during (and after) the warranty period.
For more information about Polaris, visit us online at
www.polarisindustries.com.
2
POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus-
tries Inc.
Copyright 2006 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrep-
ancies may result between the actual vehicle and the information presented in this publi-
cation. Depictions and/or procedures in this publication are intended for reference use
only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse
of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.
Printed in U.S.A.
2007 Sportsman 500/800 EFI International Owner’s Manual
P/N 9920699
3
TABLE OF CONTENTS
Know Your Vehicle . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Features and Controls . . . . . . . . . . . . . . . . . . . 34
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Emission Control Systems . . . . . . . . . . . . . . . 58
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 122
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 126
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 127
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 134
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
4
KNOW YOUR VEHICLE
As the operator of the vehicle, you are responsible for your personal
safety, the safety of others, and the protection of our environment. Read
and understand your owner's manual, which includes valuable informa-
tion about all aspects of your vehicle, including safe operating proce-
dures.
Ride responsibly. Know all laws and regulations concerning the opera-
tion of this vehicle in your area.
Vehicle Identification Numbers
Record your vehicle's identification numbers and key number in the
spaces provided. Remove the spare key and store it in a safe place. An
ignition key can be duplicated only by ordering a Polaris key blank
(using your key number) and mating it with one of your existing keys.
The ignition switch must be replaced if all keys are lost.
Vehicle Model Number: ___________________________________________________
Frame VIN: ____________________________________________________________
Engine Serial Number: ___________________________________________________
Key Number: ___________________________________________________________
####
VIN
Engine Serial Number
Key Number
5
SAFETY
Operator Safety
The following signal words and symbols appear throughout this manual
and on your vehicle. Your safety is involved when these words and sym-
bols are used. Become familiar with their meanings before reading the
manual.
The safety alert symbol, on your vehicle or in this manual, alerts you to the
potential for injury.
WARNING
The safety alert warning indicates a potential hazard that may result in serious
injury or death.
CAUTION
The safety alert caution indicates a potential hazard that may result in minor
injury or damage to the vehicle.
CAUTION
A caution indicates a situation that may result in damage to the vehicle.
NOTE
A note will alert you to important information or instructions.
6
SAFETY
Operator Safety
Safety Training
When you purchased your new Quadricycle, your dealer offered a
hands-on safety training course. You were also provided with printed
materials that explain safe operating procedures. Review this informa-
tion on a regular basis.
If you purchased a used Polaris Quadricycle from a party other than a
Polaris dealer, please request free safety training from any authorized
Polaris dealer.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age.
Restrictions
This vehicle is approved for OFF-ROAD TOWING ONLY. Operating a
Quadricycle/trailer combination on public roads is prohibited.
Equipment Modifications
The warranty on your Polaris Quadricycle may be terminated if any
equipment has been added, or if any modifications have been made, that
increase speed or power.
NOTE: The addition of certain accessories, including (but not limited to) mow-
ers, blades, tires, sprayers and large racks may change vehicle han-
dling. Use only Polaris-approved accessories. Know their function and
effect on the vehicle.
WARNING
Failure to follow the warnings in this manual can result in serious injury or
death. A Polaris Quadricycle is not a toy and can be hazardous to operate. A
collision or rollover can occur quickly, even during routine maneuvers, if you
fail to take proper precautions.
Read and understand your owner's manual and all warnings before operating
a Polaris Quadricycle.
7
SAFETY
Operator Safety
Read and understand all warnings,
cautions and operating procedures in
this manual and on the safety labels
before operating the Quadricycle.
Read and understand all warnings,
cautions and operating procedures in
this manual and on the safety labels
before operating the Quadricycle.
Never operate a Quadricycle without proper instruction. Take a training course.
Beginners should receive training from a certified instructor. Contact an
authorized Polaris Quadricycle dealer or call Polaris at 1-800-342-3764.
Never permit others to operate the Quadricycle unless they have read and
understand this manual and all product labels, and have completed a certified
safety training course.
Never allow anyone under 16 years of
age to operate this vehicle.
Never carry a passenger. The purpose
of the long seat is to allow the operator
to shift position.
WARNING
Serious injury or death can result if you do not follow the instructions and
procedures listed here and throughout this manual.
8
SAFETY
Operator Safety
Always wear an approved helmet that
fits properly. Wear eye protection
(goggles or face shield), gloves,
boots, long sleeves and long pants.
Never consume alcohol or drugs
before or while operating a
Quadricycle.
Never operate at excessive speeds.
Travel and turn at speeds appropriate
for the terrain, visibility, operating
conditions and your experience.
Never attempt jumps or other stunts.
9
SAFETY
Operator Safety
Always inspect your Quadricycle
before each use to verify that it's in
safe operating condition. Follow the
inspection and maintenance
procedures outlined in this manual.
See page 55.
Keep both hands on the handlebars.
Keep your feet on the footrests.
Always travel slowly when operating
on unfamiliar terrain. Use extra
caution.
Use caution when operating on rough,
slippery or loose terrain.
Always follow the procedures outlined
in this manual for turning. See page
19.
Never turn sharply at excessive
speeds, which can lead to vehicle
overturn.
10
SAFETY
Operator Safety
If a Quadricycle has been involved in
an accident, always have an
authorized Polaris dealer inspect the
entire vehicle for possible damage,
including (but not limited to) brake,
throttle and steering systems.
Never operate on hills too steep for
the Quadricycle or for your abilities.
Practice on smaller hills before
attempting larger hills. Avoid climbing
hills steeper than 25°.
Always follow the procedures outlined
in this manual for climbing hills. See
page 22.
Always follow the procedures outlined
in this manual for driving downhill and
for braking on hills. See page 25.
Always follow the procedures outlined
in this manual for crossing the side of
a hill. See page 24.
Never attempt to turn the Quadricycle
around on any hill until you've
mastered (on level ground) the turning
technique outlined in this manual.
11
SAFETY
Operator Safety
Always follow the procedures outlined
in this manual for braking if you stall or
roll backwards while climbing a hill.
Never back down a hill. See page 26.
Always follow the procedures outlined
in this manual for operating over
obstacles. See page 21.
Always follow the procedures outlined
in this manual for operating on
slippery or loose surfaces. Use extra
caution. Always avoid skidding or
sliding. See page 20.
Always follow the procedures outlined
in this manual for driving through
water. Never drive through deep or
fast-flowing water. See page 28.
12
SAFETY
Operator Safety
Always follow the procedures outlined
in this manual for driving in reverse.
See page 31.
Always use the size and type of tires
specified for your Quadricycle.
Maintain the proper tire pressure.
Never modify a Quadricycle through
improper installation or use of
accessories.
Never exceed the stated load capacity
for your Quadricycle. Cargo must be
properly distributed and securely
attached. Reduce speed and follow
the instructions in this manual for
carrying cargo or towing. Allow a
greater distance for braking.
13
SAFETY
Operator Safety
Never operate the Quadricycle on a
frozen body of water.
Operating on paved surfaces may
affect the handling and control of the
Quadricycle and could result in loss of
control. Avoid sudden turns or swift
movement of the handlebars.
Always remove the ignition key when
the vehicle is not in use to prevent
unauthorized use or accidental
starting.
Always unlock the steering before
starting the engine. See page 40.
Hot components can cause serious burns and fire. Do not touch hot exhaust
system components. Always keep combustible materials away from the exhaust
system.
For more information about Quadricycle safety,
call Polaris at 1-800-342-3764.
14
SAFETY
Safety Decals and Locations
Warning decals have been placed on the vehicle for your protection.
Read and follow the instructions on each decal carefully. If a decal
becomes illegible or comes off, contact your Polaris dealer to purchase a
replacement. Replacement safety decals are provided by Polaris at no
charge. The part number is printed on the decal.
The following pages repeat the information found on each decal.
General Alert
(Multi-Lingual)
Before you operate this
vehicle, read the owner’s
manual.
Hill Operation Alert
• Never operate this vehicle on HILLS
steeper than 25 degrees 25°.
• To prevent flip-over on hilly terrain,
when going up or down, use throttle
and brakes gradually.
+
General
Alert
+
Hill
Operation
Alert
+
Age 16
Alert
15
SAFETY
Safety Decals and Locations
“No Passenger” Warning
WARNING - NEVER ride as a passenger. Passengers can cause a loss of
control, resulting in SEVERE INJURY or DEATH.
Tire Pressure/Load Alert
TIRE PRESSURE IN PSI (KPa): FRONT 5 (34.5) REAR 5 (34.5)
MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING
MACHINE, DRIVER AND CARGO IS 1200 LBS. (546 kg). Read Owner's
Manual for more detailed loading information.
Clutch Cover Alert
NO STEP
Rack Warning, Front and Rear
WARNING - DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or
tipover may result causing severe injury or death. Tow only from tow hooks or
hitch. Maximum Rack Loads: Front 90 lbs. (41 kg) Rear 180 lbs. (82 kg)
Reverse Override Alert
Pushing reverse override button may cause sudden increases in power and
traction if too much throttle is applied. Loss of control or forward flipover may
result, especially in AWD. See Owner's Manual.
+
“No Passenger”
Warning
+
+
Rack
Warning
Rack
Warning
Tire Pressure/
Load Alert
+
+
Clutch
Cover Alert
16
SAFETY
Safe Riding Gear
Always wear protective clothing to reduce the chance of injury.
Helmet
Always wear a helmet that meets or exceeds established safety stan-
dards.
Approved helmets in the USA and Canada bear a U.S. Department of
Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania
bear the ECE 22.05 label. The ECE mark consists
of a circle surrounding the letter E, followed by the
distinguishing number of the country which has
granted approval. The approval number and serial
number will also be displayed on the label.
Helmet
Eye Protection
Gloves
Boots
Long Pants
Long
Sleeves
E
4
051039
0006.31
17
SAFETY
Safe Riding Gear
Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection. When-
ever riding a Polaris vehicle, always wear shatterproof goggles or use a
shatterproof helmet face shield. Polaris recommends wearing approved
Personal Protective Equipment (PPE) bearing markings such as VESC
8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.
Gloves
Off-road style gloves with knuckle pads are the best for comfort and
protection.
Boots
The best footwear is a pair of sturdy over-the-calf boots with low heels.
Clothing
Always wear long sleeves and long pants to protect arms and legs.
Riding pants with kneepads and a jersey with shoulder pads provide the
best protection.
18
SAFETY
Driving Safely
Driving Procedures
1. Sit upright. Keep your feet on the footrests. Keep both hands on the
handlebars.
2. Apply the brakes.
3. Start the engine and allow it to warm up.
4. Shift the transmission into gear.
5. Check your surroundings and determine your path of travel.
6. Release the brakes.
7. Slowly squeeze the throttle lever toward the handlebar to begin
driving.
8. Drive slowly. Practice maneuvering and using the throttle and
brakes on level surfaces.
19
SAFETY
Driving Safely
Turning the Vehicle
1. Before turning, activate a turn
signal to alert others of your
intentions. Activate the left
signal before a left turn. Acti-
vate the right signal before a
right turn.
2. Steer in the direction of the
turn, leaning your upper body
to the inside of the turn while
supporting your weight on the
outer footrest. Use the same
leaning technique for turning
in reverse.
3. Practice turning at slow speeds
before attempting to turn at faster speeds.
Never operate at excessive speeds.
Travel and turn at speeds appropriate
for the terrain, visibility, operating
conditions and your experience.
Always follow the procedures outlined
in this manual for turning. Never turn
sharply at excessive speeds, which
can lead to vehicle overturn.
20
SAFETY
Driving Safely
Driving on Slippery Surfaces
Whenever driving on slippery or
loose surfaces such as wet trails,
gravel, snow or ice, follow these
precautions:
1. Slow down before driving
onto slippery surfaces.
2. Engage AWD before wheels
begin to lose traction.
3. Be alert.
4. Watch the trail.
5. Avoid quick, sharp turns.
NOTE: To correct a rear wheel
skid, turn the handlebars in the same direction as the skid and shift
body weight forward.
Always follow the procedures outlined
in this manual for operating on
slippery or loose surfaces. Use extra
caution. Always avoid skidding or
sliding.
CAUTION
Severe damage to the drive train may occur if AWD is engaged while the
wheels are spinning. Engage AWD when the wheels have traction.
21
SAFETY
Driving Safely
Driving Over Obstacles
1. Always check for obstacles before operating in a new area. Serious
injury or death can result if your vehicle comes in contact with a
hidden obstacle.
2. Be alert. Watch the terrain. Use extra caution.
3. Never operate over large obstacles.
4. Avoid hazards such as logs, rocks and low branches.
Always follow the procedures outlined
in this manual for operating over
obstacles.
22
SAFETY
Driving Safely
Driving Uphill
Whenever traveling uphill, follow these precautions:
1. Avoid steep hills (25° maximum).
2. Check the terrain carefully.
3. Avoid hills with excessively slippery or loose surfaces.
4. Shift your weight uphill.
5. Drive straight uphill.
6. Keep your feet on the footrests.
7. Drive at a steady rate of speed to avoid stalling.
8. Be alert. Be prepared to take emergency action. This may
include dismounting quickly.
9. Never open the throttle suddenly or make sudden gear changes.
10. Never go over the top of a hill at high speed.
25° Maximum
23
SAFETY
Driving Safely
Driving Uphill
If all forward speed is lost:
Keep your weight uphill.
If the vehicle begins rolling downhill, never apply engine power. Never
apply the brakes aggressively while rolling backwards.
Apply the brakes gradually. When fully stopped, lock the hydraulic
parking brake. See page 39.
Dismount on the uphill side, or to either side if the vehicle is pointed
straight uphill. Turn the vehicle around using the K-Turn. See page 26.
Always follow the procedures outlined
in this manual for climbing hills. Avoid
climbing hills steeper than 25°.
Always follow the procedures outlined
in this manual for braking if you stall or
roll backwards while climbing a hill.
Never back down a hill.
24
SAFETY
Driving Safely
Driving on a Sidehill (Sidehilling)
Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is
necessary, follow these precautions:
1. Slow down.
2. Avoid hills with excessively slippery or loose surfaces.
3. Shift your weight uphill.
4. Avoid crossing the sides of steep hills.
5. Keep your feet on the footrests.
6. Steer slightly into the hill.
NOTE: If the vehicle begins to tip, quickly turn the front wheels downhill (if
possible) or dismount on the uphill side immediately!
Always follow the procedures outlined
in this manual for crossing the side of
a hill.
Never attempt to turn the Quadricycle
around on any hill until you've
mastered (on level ground) the turning
technique outlined in this manual.
25
SAFETY
Driving Safely
Driving Downhill
When driving downhill, follow
these precautions:
1. Check the terrain carefully.
2. Avoid hills with
excessively slippery or
loose surfaces.
3. Never drive downhill at
high speed.
4. Slow down.
5. Avoid driving downhill at
an angle, which can cause
the vehicle to pitch sharply
to one side. Drive straight
downhill.
6. Shift your weight rearward.
7. Apply the brakes slightly to aid in slowing.
Always follow the procedures outlined
in this manual for driving downhill and
for braking on hills.
Never operate at excessive speeds.
Travel and turn at speeds appropriate
for the terrain, visibility, operating
conditions and your experience.
26
SAFETY
Driving Safely
Turning Around on a Hill (K-Turn)
If the vehicle stalls while climbing a hill, never back it down the hill!
Use the K-turn to turn around.
1. Stop the vehicle. Keep your weight uphill.
2. Lock the hydraulic parking brake.
3. Leave the transmission in forward gear. Turn the engine off.
4. Dismount on the uphill side of the vehicle, or on the left if the vehi-
cle is pointing straight uphill.
5. Stay uphill of the vehicle and turn the handlebars full left.
6. Squeeze the brake lever to release the parking brake.
7. Slowly release the brake lever and allow the vehicle to roll around
to your right until it's pointing across the hill or slightly downward.
2.4 m
27
SAFETY
Driving Safely
Turning Around on a Hill (K-Turn)
8. Lock the hydraulic parking brake.
9. Remount from the uphill side. Keep your weight uphill.
10. Apply the foot brake.
11. With the transmission still in forward, start the engine.
12. Squeeze and release the brake lever to release the parking brake.
13. Release the foot brake and drive slowly downhill. Control speed
with either the hand or foot brake until the vehicle is on level
ground.
Always follow the procedures outlined
in this manual for climbing hills. See
page 22.
Always follow the procedures outlined
in this manual for crossing the side of
a hill. See page 24.
28
SAFETY
Driving Safely
Driving Through Water
Follow these procedures when driving through water:
1. Check water depth and current before crossing.
2. Avoid operating in water deeper than the bottom of the footrests. If
it's unavoidable, travel slowly, balance your weight carefully and
avoid sudden movements. Maintain a slow and steady forward
motion. Do not make sudden turns, stops or throttle changes.
3. Choose a crossing where both banks have gradual inclines.
4. Drive slowly. Avoid rocks and obstacles.
5. Wet brakes may have reduced stopping ability. Always test your
brakes after leaving water. If necessary, apply them lightly several
times to allow friction to dry out the pads.
Maximum Depth
29
SAFETY
Driving Safely
Driving Through Water
If your vehicle becomes fully immersed, and it's impossible to take it to
a dealer before starting it, follow the steps described on page 102. Have
the vehicle serviced by your dealer promptly.
NOTE: If water has been ingested into the transmission (PVT), follow the pro-
cedure on page 107.
Always follow the procedures outlined
in this manual for driving through
water. Never drive through deep or
fast-flowing water.
If the vehicle stops while fully submerged, major engine damage can result if the
machine is not thoroughly inspected. Take the vehicle to your dealer before
starting the engine.
30
SAFETY
Driving Safely
Parking on an Incline
Avoid parking on an incline. If it's unavoidable, follow these precau-
tions:
1. Stop the engine.
2. Place the transmission in PARK.
3. Always block the rear wheels on the downhill side.
31
SAFETY
Driving Safely
Driving in Reverse
Follow these precautions when operating in reverse:
1. Avoid backing downhill.
2. Always check for obsta-
cles or people behind the
vehicle before backing.
3. Drive slowly.
4. Apply the foot brake
lightly for stopping.
5. Avoid turning at sharp
angles.
6. Do not use the override
switch unless additional
power is required for vehicle movement. Use with caution.
NOTE: Reverse speed is greatly increased when the override switch is used.
Do not operate at full throttle. Apply just enough throttle to maintain the
desired speed.
Excessive throttle operation while in the speed limit mode may cause fuel to
build in the exhaust, resulting in engine popping and/or engine damage.
Always follow the procedures outlined
in this manual for driving in reverse.
32
SAFETY
Driving Safely
Hauling Cargo
Overloading the vehicle or carrying or towing cargo improperly can alter vehicle
handling and may cause loss of control or brake instability. Always follow these
precautions when hauling cargo.
• Read and understand the load distribution warnings listed on the vehicle
warning labels.
• Never exceed the stated load capacity for this vehicle.
• REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING
WHEN HAULING CARGO OR TOWING. Use extreme caution when applying
brakes. Avoid situations that require backing downhill.
• When operating over rough or hilly terrain, reduce speed, cargo and towed
load to maintain stable driving conditions.
• DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on
the front rack.
• CARRY LOADS AS LOW ON THE RACK AS POSSIBLE. Carrying a load
high on the rack raises the center of gravity of the vehicle and creates a less
stable operating condition. Reduce load weight when cargo is high. Secure
off-centered loads that cannot be centered and operate with extra caution.
• CARRYING A LOAD on only one rack may cause the vehicle to overturn.
Split the load between the front rack and rear rack, with 1/3 in the front and 2/
3 in the back. Do not exceed load capacities. See specifications beginning on
page 122.
• SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create
unstable operating conditions, which could result in loss of control of the vehi-
cle.
• OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When
handling off-centered loads that cannot be centered, securely fasten the load
and operate with extra caution. Always attach the tow load to the hitch point
designated for your vehicle.
• USE EXTREME CAUTION when operating with loads that extend over the
rack sides. Stability and maneuverability may be adversely affected, causing
the vehicle to overturn.
• TOWING is approved OFF-ROAD ONLY. Operating a Quadricycle/trailer
combination on public roads is prohibited.
• TOWING SPEED should never exceed 16 km/h. Never exceed 8 km/h when
towing loads in rough terrain, while cornering, or while ascending or descend-
ing hills.
33
SAFETY
Driving Safely
Hauling Cargo
Towing Loads
Towing is approved OFF-ROAD ONLY. Operating a Quadricycle/trailer
combination on public roads is prohibited. Do not exceed the maximum
capacities when towing. Do not tow any trailer on a grade steeper than
15°.
Using an improper hitch or exceeding the
maximum tongue weight capacity can
result in serious damage to the vehicle
and will void your warranty. Never install
a hitch longer than 6 3/4" (17 cm). Never
install automotive accessories on your
Polaris Quadricycle. Always install
Polaris-approved (or equivalent)
accessories designed for Quadricycle
use.
500 EFI 800 EFI
Maximum Towed Load (Level Ground) 557 kg 682 kg
Maximum Towed Load (Up to 15° Grade) 386 kg 386 kg
Maximum Vertical Hitch Weight 55 kg 68 kg
1/3
2/3
Maximum
6 3/4" (17 cm)
34
FEATURES AND CONTROLS
Switches
Mode/Reverse Override Switch
Press the switch to toggle through the speedometer display modes
(except in reverse). See page
45.
To gain additional power while operating in reverse, press the override
switch before opening the throttle. This will cancel the reverse speed
limit function.
NOTE: The override switch also allows activation of All Wheel Drive in
reverse, if the AWD switch is on.
WARNING
Activating the override switch with the throttle open and while operating in
reverse can cause loss of control. Do not activate the override switch while
the throttle is open.
Mode/Reverse
Override Switch
Main Key
Switch
Engine
Stop Switch
Headlight
Switch
All Wheel Drive
Switch
Hazard Warning
Switch
35
FEATURES AND CONTROLS
Switches
Main Key Switch
End all electrical power to the vehicle.
LIGHTS ON position turns the headlights on.
Start the engine. The headlights are not on in this position.
After starting the engine, release the key switch to the POSITION
LIGHTS ON position.
Do not attach a large key fob or key ring to the main switch. It may contact the
gas tank cap when turning, causing an interruption to the electrical system and
an unexpected engine shut-down during operation. This could result in serious
injury or death.
Engine Stop Switch
The engine will not start or run when
the switch is in the OFF position.
OFF
RUN
Light Switch
The lights do not operate unless the
main key switch is on and the engine
stop switch is in the RUN position.
High Beam
Low Beam
Engine
Stop Switch
Light
Switch
36
FEATURES AND CONTROLS
Switches
All Wheel Drive Switch
See page 44 for all wheel drive
information.
Hazard Warning Switch
Push the hazard warning
switch to cause all turn
signal lights to flash
simultaneously. Use this
feature to alert others of
an emergency or other
situation requiring
caution.
Turn Signal Switch
Push the toggle switch
either left or right to
activate the corresponding
turn signal light. The
indicator on the pod will
also flash. Return the
toggle to the center
position and push it
inward to end the signal.
Horn Switch
Press the horn switch to
sound the horn.
AWD Switch
Tu r n
Indicators
Hazard
Switch
Horn Switch
Turn Signal
Switch
37
FEATURES AND CONTROLS
Throttle Lever
Press the throttle lever to increase
engine speed and vehicle
movement. Release the lever to
reduce engine speed and vehicle
movement.
Mirrors
Use the mirrors to assist in traffic maneuvers. Always check and adjust
the mirrors before driving the Quadricycle.
Electronic Throttle Control (ETC)
ETC causes the engine to stop
if the throttle cable sticks in
an open position when the
operator releases the throttle
lever.
The Electronic Throttle Control (ETC) stops the engine in the event of a throttle
system malfunction. Do not modify the ETC system or replace it with other
throttle mechanisms.
WARNING
Failure to check or maintain proper operation of the throttle system can result
in an accident if the throttle lever sticks during operation. Check the lever for
proper operation before starting the engine. Check occasionally during
operation.
Do not start or operate a Quadricycle with sticking or improperly operating
throttle controls. Contact your dealer for repair if throttle problems arise.
Electronic Throttle Control
38
FEATURES AND CONTROLS
Foot Brake
The all-wheel foot brake is
located on the right footrest.
The foot brake operates both
front and rear brakes. Press the
brake pedal down with your
foot to apply the all-wheel
brakes.
If the rear wheels begin to skid
or slide while using the foot
brake, reduce brake pressure.
Hand Brake Lever
The hand brake operates both front
and rear brakes. Squeeze the brake
lever toward the handlebar to apply
the all-wheel brakes.
If the rear wheels begin to skid or
slide while using the brake, reduce
lever pressure.
WARNING
Aggressively applying the brakes when backing down a hill may cause rear
tipover. Aggressively applying the brakes while moving forward may cause
the rear wheels to skid and result in loss of control.
Read this owner's manual and understand the operation of all brake systems
on this vehicle. Always use caution whenever applying the brakes.
Foot Brake
39
FEATURES AND CONTROLS
Parking Brake
Locking the Parking Brake
1. Place the transmission in
PARK.
2. Squeeze the brake lever toward
the handlebar.
3. Push the parking brake lock
forward to engage the lock.
4. Release the brake lever.
5. To release the parking brake
lock, squeeze and release the
brake lever.
WARNING
Operating the Quadricycle while the parking brake is engaged could result in
an accident and serious injury or death. Always release the parking brake
lock before operating.
40
FEATURES AND CONTROLS
Steering Lock
Lock the steering to prevent unau-
thorized use or theft of the vehicle.
1. Turn the handlebars to the full
left position.
2. Insert the steering lock key
and turn it clockwise.
3. Remove the key.
4. Reverse the procedure to
unlock the steering.
The handlebars are locked in the full left position when the steering is locked.
Always unlock the steering before starting the engine.
NOTE: Place the steering lock keys in a safe place. The lock must be
replaced if the keys are lost.
41
FEATURES AND CONTROLS
Fuel Tank Cap
Remove the fuel tank cap to
add fuel to the fuel tank. Use
either leaded or unleaded gaso-
line with a minimum pump
octane of 87. Do not use E-85
fuel.
Fuel Filter
The in-line fuel filter should be
replaced by your dealer after
every 100 hours of operation or
annually. Do not attempt to
clean the fuel filter.
Fuel Tank
Cap
42
FEATURES AND CONTROLS
Transmission Gear Selector
The transmission gear
selector is located on the
right side of the vehicle.
H: High Gear
L: Low Gear
N: Neutral
R: Reverse
P: Park
Whenever the vehicle is
left unattended, always
place the transmission in
PARK. The transmission
is locked when it’s in
PARK.
Shifting gears with the engine speed above idle or while the vehicle is moving
can cause transmission damage. Stop the vehicle, release the throttle and move
the shift lever to the desired gear. See your dealer if you experience any shifting
problems.
Gear Selector
43
FEATURES AND CONTROLS
Recoil Starter (if equipped)
If the battery is too weak to start the
engine, use the recoil starter. Follow
the starting procedures on page 56,
cranking the engine with the recoil
starter instead of the main key
switch.
1. Grasp the recoil starter rope
handle tightly.
2. Pull slightly until the starter
mechanism engages.
3. Pull the rope abruptly to start the engine.
Extending the recoil starter rope until it stops can cause damage to the recoil
assembly. Do not extend the starter rope so far that it stops.
If the starter rope handle is not seated properly, water may enter the recoil
housing and damage components. Make sure the handle is fully seated on the
recoil housing, especially when traveling in wet areas.
Recoil Starter
Handle
44
FEATURES AND CONTROLS
All Wheel Drive (AWD) System
The AWD switch may be turned on or off while the vehicle is moving.
AWD will not engage until engine speed is below 3100 RPM. AWD
remains engaged until the switch is turned off. There is no limit to the
length of time the vehicle may remain in AWD.
If the switch is turned off while the demand drive unit is engaged, it will
not disengage until the rear wheels regain traction. Engage AWD before
getting into situations where maximum traction is needed. If the rear
wheels are spinning, release the throttle before switching to AWD.
NOTE: The override switch allows activation of AWD in reverse if the AWD
switch is on. See page 34.
Switching to AWD while the rear wheels are spinning may cause severe drive
shaft and gearcase damage. Always switch to AWD while the rear wheels have
traction or are at rest.
AWD
When the AWD switch is on,
the Quadricycle is in four-
wheel drive and the differential
is locked, providing maximum
traction. The demand drive
unit automatically engages
when the rear wheels lose trac-
tion. When the rear wheels
regain traction, the demand drive unit automatically disengages.
2X4
When the 2X4 switch is on,
the Quadricycle is in two-
wheel drive at all times and
the differential is locked.
45
FEATURES AND CONTROLS
Instrument Cluster
Your vehicle is equipped with an instrument cluster that senses vehicle
speed from the right front wheel. The instrument cluster measures dis-
tance in miles as well as hours of operation. It also includes a reverse
speed limiter function that limits the vehicle's speed to approximately 7-
9 mph. Refer to page 34 for additional information.
NOTE: In addition to showing vehicle speed, the speedometer needle flashes
when a warning condition exists.
High water pressure may damage vehicle components. Wash the vehicle by
hand or with a garden hose using mild soap.
Certain products, including insect repellents and chemicals, will damage the
speedometer lens and other plastic surfaces. Do not use alcohol to clean the
instrument cluster. Do not allow insect sprays to contact the lens. Immediately
clean off any gasoline that splashes on the instrument cluster.
Rider
Information
Center
Speedometer
Needle
Speedometer
46
FEATURES AND CONTROLS
Instrument Cluster
Rider Information Center
The rider information center is located in the instrument cluster. All seg-
ments will light up for 2.5 seconds at start-up.
NOTE: If the instrument cluster fails to illuminate, a battery over-voltage may
have occurred and the instrument cluster may have shut off to protect
the electronic speedometer. If this occurs, take the vehicle to your
Polaris dealer for proper diagnosis.
1. Gear Indicator - This
indicator displays gear
shifter position:
H = High Gear
L = Low Gear
N = Neutral
R = Reverse Gear
P = Park
2. AWD Indicator - This
indicator illuminates
when the AWD switch
is in the AWD position.
3. Engine Hour Display Indicator
4. Service Interval/Diagnostic Mode Indicator
5. Odometer/Tachometer/Tripmeter/ Hour Meter/Clock
6. Fuel Gauge - The segments of the fuel gauge show the level of fuel
in the fuel tank. When the last segment clears, a low fuel warning is
activated. All segments will flash, FUEL will display in the LCD,
and the speedometer needle will blink. Refuel immediately.
7. Check Engine Warning Indicator - This indicator serves two pur-
poses. The word HOT displays if the engine overheats. It also
appears if an EFI-related fault occurs. Do not operate the vehicle if
this warning appears. Serious engine damage could result.
8. Mode Indicator
1
2
34
5
6
8
7
47
FEATURES AND CONTROLS
Instrument Cluster
Rider Information Center
Standard Modes
Use the MODE button to toggle through the mode options. The reverse
override button is also the MODE button. See page 34.
NOTE: The transmission cannot be in reverse when using this feature.
Odometer Mode
The odometer records the miles traveled by the vehicle.
Trip Meter Mode
The trip meter records the miles traveled by the vehicle on each trip if
it's reset before each trip. To reset the trip meter, select the trip meter
mode. Press and hold the mode button (override button) until the total
changes to 0.
NOTE: In the Rider Information Center, the trip meter display contains a deci-
mal point, but the odometer displays without a decimal point.
Hour Meter Mode
This mode logs the total hours the engine has been in operation.
Tachometer Mode
The engine RPM is displayed digitally.
NOTE: Small fluctuations in the RPM from day to day may be normal because
of changes in humidity, temperature and elevation.
Clock Mode
The clock displays time in a 12-hour format. To reset the clock, see page
48.
48
FEATURES AND CONTROLS
Instrument Cluster
Rider Information Center
Diagnostic Mode
The wrench icon will display when the gauge is in the diagnostic mode.
To exit the diagnostic mode, turn the key switch off and on. Any move-
ment of the tires will also cause the gauge to exit the diagnostic mode.
To enter the diagnostics mode:
1. Turn the key switch off and wait 10 seconds.
2. Lock the parking brake.
3. Place the transmission in neutral.
4. Hold the mode/reverse override button and turn the key switch on.
Release the switch as soon as the display is activated.
5. Use the mode button to toggle through the diagnostic screens.
Clock Screen
To reset the clock:
1. Enter the diagnostic mode.
2. Toggle to the clock screen.
3. Press and hold the mode button until the hour display flashes.
Release the button.
4. Press and release the mode button once to advance the setting by
one hour. Press and hold the mode button to advance the hours
quickly.
5. When the desired hour is displayed, wait approximately four sec-
onds, until the minute display flashes.
6. When the display stops flashing, the mode has been set.
7. Use the same procedure to reset the minutes.
49
FEATURES AND CONTROLS
Instrument Cluster
Rider Information Center
Diagnostic Mode
Battery Voltage Screen
View this screen to check battery voltage level.
Tachometer Screen
View the tachometer to check engine speed.
AWD Diagnostic Screen
The gauge indicates whether or not current is flowing through the AWD
coil (only on models with switchable AWD). This screen is for informa-
tional purposes only. Please see your dealer for all major repairs.
Gear Circuit Diagnostic Screen
This screen displays the resistance value (in ohms) being read at the
gear switch input of the gauge. This screen is for informational purposes
only. Please see your dealer for all major repairs.
Programmable service interval
When the hours of engine operation equal the programmed service
interval setting, the wrench icon will flash for 5 seconds each time the
engine is started. When this feature is enabled, it provides a convenient
reminder to perform routine maintenance. See page 50.
NOTE: The service interval is programmed at 50 hours at the factory.
50
FEATURES AND CONTROLS
Instrument Cluster
Rider Information Center
Diagnostic Mode
Programmable service interval
To enable or disable the service interval:
1. Enter the diagnostic mode.
2. Toggle to the service interval screen.
3. Press and hold the mode button for about 7 seconds, until either ON
or OFF appears in the Rider Information Center, depending on your
preference.
To reset the service interval:
1. Enter the diagnostic mode.
2. Toggle to the service interval screen.
3. Press and hold the mode button for 2-3 seconds, until the wrench
icon flashes. Release the button.
4. Press and release the mode button once to advance the setting by
one hour. Press and hold the mode button to advance the hours
quickly.
NOTE: If you scroll past the intended number, press and hold the button until
the hours cycle back to zero.
5. When the desired setting is displayed, wait until the wrench icon
stops flashing. The new service interval is now programmed.
Miles/Kilometers toggle
The display in the tripmeter and odometer can be changed to display
either standard or metric units of measurement.
1. Enter the diagnostic mode.
2. Toggle to the screen that displays either kilometers (KM) or miles
(MP).
3. Press and hold the mode button until the letters flash, then press and
release the button once. When the display stops flashing, the mode
has been set.
51
FEATURES AND CONTROLS
Instrument Cluster
Rider Information Center
Downloading Codes
The EFI diagnostic mode is for informational purposes only. Please see
your Polaris dealer for all major repairs.
See page 52 for Blink Codes and Failure Descriptions. Use the follow-
ing procedure to download blink codes (failure codes) from the EFI
module.
1. Place the transmission in
PARK. Stop the engine.
Turn the key switch to the
ON position.
2. Turn the key switch off and
on three times in less than
five seconds. The word
“WAIt” will appear on the
screen.
3. The Check Engine icon will blink once, pause, then blink twice
(blink code 12) to begin the diagnostic sequence. The EFI module is
now searching for blink codes. If a code exists, the Check Engine
icon will flash the code.
4. Count the number of times the Check Engine icon flashes.
Example: For the two blink codes 42 and 36, the Check Engine icon will
flash 4 times, pause, then flash 2 times (code 42), then pause longer,
blink 3 times, pause, and blink 6 times (code 36).
5. A code 61 will signal the end of the sequence. If no blink codes are
found, only codes 12 and 61 will appear during the sequence.
NOTE: The word “WAIt” will remain on the screen through this entire process.
52
FEATURES AND CONTROLS
Instrument Cluster
Rider Information Center
Downloading Codes
Blink
Code
Failure Description
12 BEGIN SEQUENCE
45 Barometric Pressure/Manifold Air Pressure Sensor Low
46 Barometric Pressure/Manifold Air Pressure Sensor High
41 Air Temp Sensor Low Voltage
41 Air Temp Sensor High Voltage
42 Engine Coolant Temp Low Voltage
42 Engine Coolant Temp High Voltage
22 Throttle Position Sensor Low
22 Throttle Position Sensor High
51 Injector Circuit Malfunction - Cyl 1: Open Load/Short-to-Ground
51 Injector Circuit Malfunction - Cyl 1: Shorted Load/Short-to-Battery
52 Injector Circuit Malfunction - Cyl 2: Open Load/Short-to-Ground
52 Injector Circuit Malfunction - Cyl 2: Shorted Load/Short-to-Battery
56 Fuel Pump: Open Load/Short-to-Ground
56 Fuel Pump: Shorted Load/Short-to-Battery
44 Crank Position Sensor Circuit Fault
36 Ignition Coil A Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground
36 Ignition Coil A Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery
37 Ignition Coil B Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground
37 Ignition Coil B Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery
31 System Voltage Low
31 System Voltage High
55 MIL Circuit: Open Load/Short-to-Ground
55 MIL Circuit: Shorted Load/Short-to-Battery
58 Fan Circuit: Open Load/Short-to-Ground
58 Fan Circuit: Shorted Load/Short-to-Battery
47 IAC Stepper Motor: Open Load
47 IAC Stepper Motor: Short-to-Ground
61 END SEQUENCE
53
OPERATION
Fuel Safety
WARNING
Gasoline is highly flammable and explosive under certain conditions.
• Use extreme caution whenever handling gasoline.
• Refuel with the engine stopped. Refuel outdoors or in a well-ventilated
area.
• Never fill a fuel container while it's on the vehicle. Static electricity between
the rack and container could cause a spark.
• Do not smoke or allow open flames or sparks in or near the area where
refueling is performed or where gasoline is stored.
• Do not overfill the tank. Do not fill the tank neck.
• If gasoline spills on your skin or clothing, immediately wash it off with soap
and water and change clothing.
54
OPERATION
Break-In Period
The break-in period for your new Polaris Quadricycle is the first ten
hours of operation, or the time it takes to use the first two full tanks of
gasoline. No single action on your part will increase the life and perfor-
mance of your Quadricycle more than following the procedures for a
proper break-in. Careful treatment of a new engine and drive compo-
nents will result in more efficient performance and longer life for these
components.
Do not operate at full throttle or high speeds for extended periods during
the first three hours of use.
Engine and Drivetrain Break-in
1. Fill the fuel tank with the recommended fuel. See page 41.
2. Check the oil level. Add oil if necessary.
3. Select an open area that allows room to familiarize yourself with
vehicle operation and handling.
4. Drive slowly. Vary the throttle positions. Do not operate at sustained
idle.
5. Perform regular checks on fluid levels, controls and areas outlined
on the daily pre-ride inspection checklist. See page 55.
6. Pull only light loads.
7. Change the oil and filter at one month.
PVT Break-in (Clutches/Belt)
Break in the clutches and belt by operating at slower speeds during the
break-in period as recommended. Pull only light loads. Avoid aggres-
sive acceleration and high speed operation during the break-in period.
55
OPERATION
Pre-Ride Checklist
Item Remarks Page
Foot brake Ensure proper operation 38
Hand brake/lever travel Ensure proper operation 87
Brake fluid Ensure proper level 84
Front suspension Inspect, lubricate if necessary 64
Rear suspension Inspect, lubricate if necessary 64
Steering/steering lock Unlock the steering; ensure free oper-
ation
40
Tires Inspect condition and pressure 92
Wheels/fasteners Inspect, ensure fastener tightness 92
Frame nuts, bolts, fasteners Inspect, ensure tightness -
Fuel and oil Ensure proper levels 41
66
71
Throttle Ensure proper operation 37
91
Indicator lights/switches Ensure proper operation 34
Engine stop switch Ensure proper operation 35
Mirrors Adjust for best side/rear vision 37
Air filter, pre-filter Inspect, clean 94
Air box sediment tube Drain deposits whenever visible -
Headlamp Check operation, apply Polaris dielec-
tric grease when lamp is replaced
97
Brake light/tail lamp Check operation, apply Polaris dielec-
tric grease when lamp is replaced
98
Riding gear Wear approved helmet, goggles, and
protective clothing
16
56
OPERATION
Starting the Engine
Operating the vehicle immediately after starting could cause engine damage.
Allow the engine to warm up for several minutes before operating.
1. Position the vehicle on a level
surface.
2. Place the transmission in
PARK.
3. Sit on the vehicle.
NOTE: The starter interlock will prevent the engine from starting if the trans-
mission is in gear and the brake is not engaged.
4. Move the engine stop
switch to RUN.
NOTE: Do not press the throt-
tle while starting the
engine.
WARNING
Engine exhaust contains poisonous carbon monoxide and can cause loss of
consciousness resulting in severe injury or death. Never run an engine in an
enclosed area.
57
OPERATION
Starting the Engine
5. Turn the ignition key past the POSITION
LIGHTS ON position to engage the
starter. Activate the starter for a maxi-
mum of five seconds, releasing the key
when the engine starts.
6. If the engine does not start, release the
starter and wait five seconds.
7. Repeat steps 5 and 6 until the engine
starts.
Cold Weather Operation
Internal engine condensation increases as outside temperatures
decrease. If the vehicle is used year-round, check the oil level fre-
quently. A rising oil level could indicate condensation in the bottom of
the oil tank, which can lead to engine damage. Any condensation must
be drained.
Always operate the engine long enough to reach operating temperature,
which reduces condensation. See your Polaris dealer for engine heater
kits, which provide quicker warm-ups and easier starting in cold
weather.
PVT System
When To Use Low Range and High Range
Condition Range to Use
Operating at speeds less than 7 MPH (11 km/h) Low
Towing heavy loads Low
Operating in rough terrain (swamps, mountains, etc.) Low
Operating at speeds greater than 7 MPH (11 km/h) High
58
EMISSION CONTROL SYSTEMS
Noise Emission Control System
Do not modify the engine, intake or exhaust components, as doing so
may affect compliance with governmental noise level requirements.
Spark Arrestor
Your Polaris vehicle has a spark arrestor that was designed for on-road
and off-road operation. It is required that this spark arrestor remain
installed and functional when the vehicle is operated.
Exhaust Emission Control System
Exhaust emissions are controlled by engine design. An electronic fuel
injection (EFI) system controls fuel delivery. The engine and EFI com-
ponents are set at the factory for optimal performance and are not
adjustable.
Electromagnetic Interference
This spark ignition system complies with USA requirements, Canadian
ICES-002 and European directives 89/336/EEC and 97/24/EC.
59
MAINTENANCE
Periodic Maintenance Chart
Maintenance intervals in the following chart are based upon average
riding conditions. Vehicles subjected to severe use must be inspected
and serviced more frequently.
The programmable service interval mode on the instrument cluster will
help determine when maintenance service is due. See page 45.
Record maintenance and service in the Maintenance Log beginning on
page 134.
NOTE: Service and adjustments are important for proper vehicle operation. If
you're not familiar with safe service and adjustment procedures, have
a qualified dealer perform these operations.
Severe Use Definition
• Frequent immersion in mud, water or sand
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold
weather can indicate contaminants collecting in the oil sump or crank-
case. Change oil immediately if the oil level begins to rise. Monitor the
oil level, and if it continues to rise, discontinue use and determine the
cause or see your dealer.
60
MAINTENANCE
Periodic Maintenance Chart
Maintenance Chart Key
X Perform these operations more often for vehicles subjected to
severe use.
E Emission-related service (Failure to conduct this maintenance will
not void the emissions warranty but may affect emissions.)
Q Have an authorized Polaris dealer perform these services.
WARNING
Improperly performing the procedures marked with a Q could result in
component failure and lead to serious injury or death. Have an authorized
Polaris dealer perform these services.
61
MAINTENANCE
Periodic Maintenance Chart
Perform all services at whichever maintenance interval is reached first.
X Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service
Q Have an authorized Polaris dealer perform these services.
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Kilometers
Steering - Pre-Ride - Make adjustments as need
ed. See Pre-Ride Checklist
on page 55.
Front suspension - Pre-Ride -
Rear suspension - Pre-Ride -
Tires - Pre-Ride -
Brake fluid level - Pre-Ride -
Brake lever - Pre-Ride -
Foot brake - Pre-Ride
Brake system - Pre-Ride -
Wheels/fasteners - Pre-Ride -
Frame fasteners - Pre-Ride -
X Engine oil level - Pre-Ride -
X
E
Air filter, pre-filter - Daily - Inspect; clean often; replace
as needed
X Air box sediment
tube
- Daily - Drain deposits when visible
Coolant - Daily - Check level daily, change
coolant every 2 years
Headlamp/tail
lamp
- Daily - Check operation; apply
dielectric grease if replacing
X
E
Air filter,
main element
- Weekly - Inspect; replace as needed
Recoil housing
(if applicable)
- Weekly - Drain water as needed,
check often if operating in wet
conditions
X
Q
Brake pad wear 10 Monthly 100 Inspect periodically
Battery 20 Monthly 200 Check terminals; clean; test
X Demand drive unit
oil (front gearcase)
25 Monthly 250 Inspect level; change yearly
X Rear gearcase oil
(if equipped)
25 Monthly 250 Inspect level; change yearly
X Transmission oil 25 Monthly 250 Inspect level; change yearly
X
E
Engine breather
filter (if equipped)
25 Monthly 250 Inspect; clean if needed
62
MAINTENANCE
Periodic Maintenance Chart
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
X Engine oil change
(break-in)
- 1 M - Perform a break-in oil change
at one month
X General
lubrication
50 3 M 500 Lubricate all fittings, pivots,
cables, etc.
Shift linkage 50 6 M 500 Inspect, lubricate, adjust
Q Steering 50 6 M 500 Lubricate
X Front suspension 50 6 M 500 Lubricate
X Rear suspension 50 6 M 500 Lubricate
Q
E
Throttle Cable/
ETC Switch
50 6 M 500 Inspect; adjust; lubricate;
replace if necessary
E Throttle Body
Intake Duct
50 6 M 500 Inspect duct for proper seal-
ing/air leaks
Drive belt 50 6 M 500 Inspect; adjust; replace as
needed
Cooling system 50 6 500 Inspect coolant strength
seasonally; pressure test
system yearly
X Engine oil change 100 6 M 1000 Perform a break-in oil change
at one month
X Oil filter change 100 6 M 1000 Replace with oil change
X Oil tank vent hose
(if equipped)
100 6 M 1000 Inspect routing, condition
Q
E
Valve clearance 100 12 M 1000 Inspect; adjust
Q
E
Fuel system 100 12 M 1000 Check for leaks at tank cap,
lines, filter, pump; replace
lines every two years
X
Q
E
Fuel filter 100 12 M 1000 Replace annually
X Radiator 100 12 M 1000 Inspect; clean external
surfaces
X Cooling hoses 100 12 M 1000 Inspect for leaks
X Engine mounts 100 12 M 1000 Inspect
Exhaust muffler/
pipe
100 12 M 1000 Inspect
63
MAINTENANCE
Periodic Maintenance Chart
X Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service
Q Have an authorized Polaris dealer perform these services.
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
Q
E
Spark plug 100 12 M 1000 Inspect; replace as needed
X Wiring 100 12 M 1000 Inspect for wear, routing,
security; apply dielectric
grease to connectors
subjected to water, mud, etc.
Q
Clutches (drive
and driven)
100 12 M 1000 Inspect; clean; replace worn
parts
Q
Front wheel
bearings
100 12 M 1000 Inspect; replace as needed
Q
Brake fluid 200 24 M 2000 Change every two years
Spark arrestor 300 36 M 3000 Clean out
Q
Toe adjustment - Inspect periodically; adjust
when parts are replaced
Q
Brakes - Inspect daily; adjust as
needed
Headlight aim - Adjust as needed
64
MAINTENANCE
Lubrication Guide
Always check and change fluids and lubricate greaseable compo-
nents at the intervals outlined in the Periodic Maintenance Chart
beginning on page 59. Items not listed in the chart should be lubri-
cated at the General Lubrication interval.
Item Lube Method
Engine Oil Polaris Premium 4 Synthetic
0W-40
See page 65.
Brake Fluid DOT 4 Only See page 84.
Transmission Oil Polaris AGL Synthetic
Gearcase Lube
See page 74.
Front Demand Drive Unit
(Front Gearcase)
Premium Demand Drive Hub
Fluid
See page 78.
Rear Gearcase Oil ATV Angle Drive Fluid (or
GL5 80-90 weight gear lube)
See page 80.
Front Prop Shaft Yoke Polaris Premium U-Joint
Lube
Grease fittings (3 pumps maxi-
mum) every 800 km, before long
periods of storage, or after pres-
sure washing or submerging.
Front Prop Shaft Yoke
65
MAINTENANCE
Engine Oil
Oil Recommendations
Always change the oil filter whenever changing oil.
Polaris recommends the use of Premium 4 Synthetic 0W-40 engine oil
for this engine. Premium 4 is a fully synthetic, high performance, multi-
viscosity oil designed to provide the ultimate in lubrication performance
and protection. See page 126 for the part numbers of Polaris products.
Oil may need to be changed more frequently if Polaris Premium 4 oil is
not used. Follow the manufacturer's recommendations for ambient tem-
perature operation.
Mixing brands or using a non-recommended oil may cause serious engine
damage. Always use a recommended oil. Never substitute or mix oil brands.
Oil Specifications
Model Lubricant Capacity Drain Plug Torque
500 EFI Premium 4 Synthetic
0W-40
1.9 liters 19-23 N-m
800 EFI Premium 4 Synthetic
0W-40
1.9 liters 27 N-m
66
MAINTENANCE
Engine Oil
Oil Level (500 EFI)
1. Position the vehicle on a level
surface.
2. Place the transmission in PARK.
3. Start the engine. Allow it to idle
for 30 seconds.
4. Stop the engine.
5. Remove the dipstick.
Wipe it dry with a clean
cloth.
6. Reinstall the dipstick
completely.
7. Remove the dipstick and check the oil level. Add oil as needed.
Maintain the oil level in the safe range. Do not overfill.
8. Reinstall the dipstick.
Dipstick
Safe
Add Oil
Safe Range
{
67
MAINTENANCE
Engine Oil
Oil Change (500 EFI)
1. Position the vehicle on a level
surface.
2. Place the transmission in PARK.
3. Start the engine. Allow it to idle
for two minutes.
4. Stop the engine.
5. Clean the area
around the drain
plug.
6. Place a drain pan
under the oil tank.
7. Remove the drain
plug.
8. Drain the oil.
9. Clean the drain plug. Reinstall the drain
plug with a new sealing washer.
10. Torque to specification. See page 65.
CAUTION
Hot oil may result in serious burns. Do not allow hot oil to contact skin.
Drain
Plug
New Sealing Washer
Screen
Fitting
68
MAINTENANCE
Engine Oil
Oil Change (500 EFI)
11. Disconnect the lower oil deliv-
ery hose and remove the screen
fitting from the oil tank. Clean
the fitting.
NOTE: The fitting threads must be
sealed with LOCTITE PST
505 or PTFE seal tape.
12. Reinstall the screen fitting and
rotate the fitting clockwise a
minimum of 2 1/2 turns into the
tank threads. Continue to rotate
the fitting until the nipple of the fitting aligns with the mark on the
tank.
NOTE: Do not over-tighten. Maximum torque for the screen fitting is 34 N-m.
13. Reattach the oil line.
14. Place towels under the oil filter.
Using an oil filter wrench, turn the
filter counterclockwise to remove it.
15. Clean the filter sealing area on the
crankcase.
16. Lubricate the filter o-ring. Check to make
sure the o-ring is in good condition.
17. Install the new oil filter. After the filter
contacts the crankcase surface, turn it 1/2
turn by hand.
18. Approximately one cup of engine oil will remain in the crankcase.
To drain, remove the drain plug on the lower right side of the crank-
case.
NOTE: The sealing surfaces on the drain plug and crankcase should be clean
and free of burrs, nicks or scratches.
19. Reinstall the drain plug. Torque to 19 N-m.
Alignment Mark
69
MAINTENANCE
Engine Oil
Oil Change (500 EFI)
20. Remove the dipstick.
21. Add 1.9 liters of recommended
oil.
NOTE: If the sump is not drained,
add about 1.6 liters initially.
22. Reinstall the dipstick.
23. Place the transmission in PARK.
24. Prime the oil pump using the procedure
on page 70.
25. Stop the engine. Check for oil leaks.
26. Check the oil level.
Add oil as needed.
Maintain the oil level
in the safe range. Do
not overfill.
27. Reinstall the dipstick.
28. Discard used oil and
filter properly.
Safe
Add Oil
Safe Range
{
70
MAINTENANCE
Engine Oil
Oil Change (500 EFI)
Oil Pump Priming
This priming procedure must be
performed whenever the oil hose
connection between the oil tank and
pump inlet has been disconnected.
1. Clamp the vent line 5 cm from
the oil tank, between the end of
the oil tank vent fitting and the
vent line's pressure relief slit.
2. Start the engine. Allow it to idle
for 10-20 seconds.
3. Remove the vent line clamp. If
the line is bled properly, you should hear a rush of air. If you do not
hear a rush of air, repeat the priming procedure.
Clamp
Pressure
Relief Slit
Tank
5 cm
71
MAINTENANCE
Engine Oil
Oil Level (800 EFI)
The oil dipstick is on the left side of the vehicle.
1. Position the vehicle on a level
surface.
2. Lift the lever lock. Remove the
dipstick. Wipe it dry with a
clean cloth.
3. Reinstall the dipstick com-
pletely, but do not lock it.
4. Remove the dipstick and check
the oil level on the top side of
the dipstick.
5. Maintain the oil level in the
safe range. Do not overfill.
NOTE: The oil level will read higher
on the bottom side of the dip-
stick. Always read the level on
the upper surface of the dip-
stick.
6. Reinstall the dipstick.
7. Secure the lever lock.
CAUTION
Hot oil may result in serious burns. Do not allow hot oil to contact skin.
Dipstick
Safe
Add Oil
{
Safe
Range
Check Level
on Top Side
72
MAINTENANCE
Engine Oil
Oil Change (800 EFI)
1. Position the vehicle on a level
surface.
2. Place the transmission in PARK.
3. Start the engine. Allow it to idle
for 2-3 minutes.
4. Stop the engine.
5. Clean the area around
the drain plug.
6. Remove the drain plug.
Drain the oil into a drain
pan.
7. Clean the drain plug.
Reinstall the drain plug
with a new sealing
washer.
8. Torque to specification.
See page 65.
9. Place towels under the oil filter.
Using an oil filter wrench, turn
the filter counterclockwise to
remove it.
10. Clean the filter sealing area on
the crankcase.
Drain Plug Location
to front
73
MAINTENANCE
Engine Oil
Oil Change (800 EFI)
11. Lubricate the filter o-ring. Check to make
sure the o-ring is in good condition.
12. Install the new oil filter. After the filter
contacts the crankcase surface, turn it 1/2
turn by hand.
13. Remove the dipstick.
14. Add 1.9 liters of recommended oil.
15. Place the transmission in
PARK.
16. Start the engine. Allow it
to idle for 1-2 minutes.
17. Stop the engine.
18. Check for leaks.
19. Check the oil level. Add oil as
needed. Maintain the oil level in the
safe range. Do not overfill.
20. Discard used oil and filter properly.
Safe
Add Oil
{
Safe
Range
74
MAINTENANCE
Transmission Oil
Maintain the oil level at the bottom of the fill plug hole. Use the
recommended oil.
See page 126 for the part numbers of Polaris products.
Oil Recommendations
Oil Level (500 EFI)
1. Position the vehicle on a level
surface.
2. Place the transmission in PARK.
3. Remove the fill plug.
4. Check the oil level.
Maintain the level at the
bottom of the fill hole
threads.
5. Add the recommended
oil as needed. Do not
overfill.
6. Reinstall the fill plug.
Torque to specification.
See page 74.
Model Lubricant Oil
Change
Capacity
Fill Plug
To r q u e
Drain Plug
To r q u e
500 EFI Premium AGL Synthetic
Gearcase Lubricant
948 ml 30 N-m 30 N-m
800 EFI Premium AGL Synthetic
Gearcase Lubricant
450 ml 19 N-m 19 N-m
Oil Level
75
MAINTENANCE
Transmission Oil
Oil Change (500 EFI)
1. Position the vehicle on a level
surface.
2. Place the transmission in PARK.
3. Remove the fill
plug.
4. Remove the drain
plug.
5. Drain the oil into a
drain pan.
6. Clean the drain
plug.
7. Reinstall the drain
plug. Torque to
specification. See
page 74.
8. Add the recommended oil. See
page 65.
9. Reinstall the fill plug. Torque
to specification. See page 74.
10. Check for leaks.
11. Discard used oil properly.
76
MAINTENANCE
Transmission Oil
Oil Level (800 EFI)
1. Position the vehicle on a level
surface.
2. Place the transmission in PARK.
3. Remove the right footwell. See
page 90.
4. Remove the fill plug.
5. Check the oil level. Maintain the
level at the bottom of the fill hole
threads.
6. Add the recommended oil as
needed. Do not overfill.
7. Reinstall the fill plug. Torque to
specification. See page 74.
View from rear
of vehicle
77
MAINTENANCE
Transmission Oil
Oil Change (800 EFI)
1. Position the vehicle on a level
surface.
2. Place the transmission in PARK.
3. Remove the right
footwell. See page
90.
4. Remove the drain
plug. Drain the oil
into a drain pan.
5. Clean the drain plug.
6. Reinstall the drain
plug. Torque to
specification. See
page 74.
7. Remove the fill plug.
8. Add the recommended oil. See
page 65.
9. Reinstall the fill plug. Torque to
specification. See page 74.
10. Check for leaks.
11. Reinstall the footwell.
12. Discard used oil properly.
Drain Plug
Access
View from front
of vehicle
to front
Bottom of vehicle
78
MAINTENANCE
Front Gearcase (Demand Drive) Fluid
Fluid Recommendations
Use the recommended fluid.
Use of other fluids may
result in improper operation
of components. See page
126 for the part numbers of
Polaris products.
Maintain the fluid level at
the bottom of the fill hole
threads.
Fluid Level
1. Position the vehicle on a level
surface.
2. Place the transmission in PARK.
3. Remove the fill plug.
4. Add the recommended demand drive fluid as needed.
5. Reinstall the fill plug. Torque to specification.
Gearcase Lubricant Capacity Fill Plug
To r q u e
Drain Plug
To r q u e
Demand Drive
Unit
Premium Demand Drive
Hub Fluid
175 ml 11-14 N-m 15 N-m
Drain Plug
Fill Plug
Fill Level
79
MAINTENANCE
Front Gearcase (Demand Drive) Fluid
Fluid Change
1. Position the vehicle on a level
surface.
2. Place the transmission in PARK.
3. Remove the fill plug.
4. Remove the drain plug.
Drain the fluid into a drain
pan.
5. Clean the drain plug.
6. Reinstall the drain plug. Torque
to specification. See page 78.
7. Add the recommended fluid.
8. Reinstall the fill plug. Torque to
specification.
9. Check for leaks.
10. Discard used oil properly.
80
MAINTENANCE
Rear Gearcase Fluid (800 EFI)
Fluid Recommendations
Fluid Level
1. Position the vehicle on a level
surface.
2. Place the transmission in PARK.
3. Remove the fill plug.
NOTE: Use a light colored non-absor-
bent object (such as a cable tie,
L-shaped wire or a small L-
shaped tool) to measure the oil
level.
4. Insert the measuring object into
the fill plug hole with the short
end pointing downward. Guide
the object (at a slight angle
downward and to the left)
approximately 5 cm into the left side of the gearcase. Remove it and
verify that oil is present on the tip.
• If oil is present, do not add oil.
• If oil is not present, add 5-10 ml of the recommended oil.
5. After adding oil, recheck the oil level. Add more oil as needed until
oil appears on the tip of the measuring object. Do not overfill.
6. Reinstall the fill plug.Torque to specification.
Lubricant Capacity Fill Plug
To r q u e
Drain Plug
To r q u e
ATV Angle Drive Fluid
(or GL5 80-90 weight gear lube)
150 ml 19 N-m 19 N-m
Measuring Tool
81
MAINTENANCE
Rear Gearcase Fluid (800 EFI)
Fluid Change
1. Position the vehicle on a level surface.
2. Remove the drain plug.
Drain the oil into a drain
pan.
3. Clean the drain plug. Rein-
stall the drain plug with a
new sealing washer.Torque
to specification.
4. Remove the fill plug. Add
150 ml of the recommended
oil. Do not overfill.
5. Reinstall the fill plug. Torque
to specification.
6. Check for leaks.
7. Discard used oil properly.
82
MAINTENANCE
Cooling System
Any time the cooling system has been drained for maintenance or repair,
replace the coolant with a fresh mixture of antifreeze and water. Drain
the cooling system every two years. Add fresh coolant.
Polaris recommends the use of Polaris Premium 60/40 anti-freeze/cool-
ant or a 50/50 mixture of high quality aluminum compatible anti-freeze/
coolant and distilled water. Polaris Premium 60/40 is premixed and
ready to use. Do not dilute with water. See page 126 for the part num-
bers of Polaris products.
NOTE: Always follow the manufacturer's mixing recommendations for the
freeze protection required in your area.
Recovery Bottle Coolant
Some coolant level drop on new machines is
normal, as the system is purging itself of trapped
air. Add coolant as needed.
NOTE: Check the coolant level in the radiator any
time the recovery bottle has run dry. Add
coolant as needed.
1. Check the coolant level when the
fluid is cool.
2. Remove the left side panel. See page
90.
NOTE: Maintain the coolant level between
the minimum and maximum marks
on the bottle (when the fluid is cool).
3. View the coolant level.
4. Add coolant as needed.
5. Reinstall the side panel.
83
MAINTENANCE
Cooling System
Radiator Coolant
1. Open the front box cover.
2. Open the access door.
3. Remove the radiator pressure cap.
4. If coolant is not visible, slowly add
coolant through the radiator filler
neck.
5. Reinstall the pressure cap.
6. Secure the access door and box
cover.
NOTE: Use of a non-standard pressure
cap will not allow the recovery
system to function properly.
Contact your dealer for the correct
replacement part.
WARNING
Escaping steam can cause severe burns. Never remove the pressure cap
while the engine is warm or hot.
84
MAINTENANCE
Brake Fluid
Check brake fluid levels for both brake systems before each ride.
Always maintain brake fluid at the recommended level. Do not overfill.
The brakes should feel firm when they're applied. Spongy or weak
brakes may indicate a fluid leak or low fluid level. A low fluid level
may also mean that brake pads are worn and need to be replaced. Do not
operate the vehicle with spongy or weak brakes. See your dealer for ser-
vice.
If the fluid level is low add DOT 4 brake fluid only. See page 126 for the
part numbers of Polaris products.
Under normal operation, the diaphragm extends into the reservoir as
fluid level drops. If the fluid level is low and the diaphragm is not
extended, a leak is likely and the diaphragm should be replaced. To
ensure proper diaphragm operation, always fill the reservoir as needed
whenever the cover is loosened or removed. Do not overfill.
WARNING
Operating the Quadricycle with a spongy brake can result in loss of braking,
which could cause an accident. Never operate the Quadricycle with spongy-
feeling brakes.
WARNING
An over-full master cylinder may cause brake drag or brake lock-up, which
could result in serious injury or death. Maintain brake fluid at the
recommended level. Do not overfill.
WARNING
Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic,
meaning it rapidly absorbs moisture from the air. The moisture causes the
boiling temperature of the brake fluid to drop, which can lead to early brake
fade and the possibility of accident or severe injury. After opening a bottle of
brake fluid, always discard any unused portion.
85
MAINTENANCE
Brake Fluid
Hand Brake
The master cylinder is
located on the left handle-
bar. Maintain the fluid level
6 mm below the top edge of
the master cylinder. Do not
overfill.
1. Position the vehicle on a
level surface. Make sure
the handlebars are straight.
2. View the fluid level
through the indicator win-
dow (eye) on the top of the
master cylinder.
NOTE: The eye will appear dark
when the fluid level is full.
When fluid is low, the eye
will be clear.
3. Add the recommended fluid as needed. Do not overfill.
Master
Cylinder
Indicator
Window
Full
Low
86
MAINTENANCE
Brake Fluid
Foot Brake
1. Position the vehicle on a
level surface.
2. Remove the seat.
3. View the fluid level in the
master cylinder.
4. Maintain the fluid level
between the minimum
and maximum marks. Do
not overfill.
Minimum
Maximum
87
MAINTENANCE
Brakes
The front and rear brakes are hydraulic disc brakes, activated by apply-
ing the foot brake. The handlebar brake is also hydraulic. Both brake
systems are self-adjusting.
Brake Inspections
Perform the following checks to keep the brake systems in good operat-
ing condition. Check more often if brakes are used heavily under normal
operation.
1. Always keep brake fluid at an adequate
level. See page 84.
2. Check the brake systems regularly for
fluid leaks.
3. Check the brakes for excessive travel or
spongy feel.
4. Check the friction pads for wear, damage
and looseness. Replace the pads when
the friction material is worn to 1 mm.
5. Check the security and surface condition
of the disc.
1 mm
88
MAINTENANCE
Toe Alignment
Use the following procedure to check the toe alignment of the vehicle.
The recommended toe alignment is 3-6 mm toe out.
1. Place the handlebars
in a straight-ahead
position.
2. Place stands in front
of the vehicle, per-
pendicular to the rear
tires.
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.
4. Measure the distance
from the string to the
rim at the front and
rear of the front rim.
Rear measurement
should be 2-3 mm more than the front measurement.
NOTE: If you discover improper alignment, see your Polaris dealer for service.
WARNING
Do not attempt to adjust alignment. All steering adjustments should be
performed by an authorized Polaris dealer.
String
Stands
Rear of
Front Rim
Front of
Front Rim
89
MAINTENANCE
Steering Assembly
Check the steering assembly of the vehicle periodically for loose nuts
and bolts. If loose nuts and bolts are found, see your Polaris dealer for
service before operating the vehicle.
Handlebar Adjustment
The handlebars can be adjusted for rider preference.
1. Remove the upper headlight
pod.
2. Loosen the four handlebar bolts.
3. Adjust the handlebar to the
desired height.
NOTE: Be sure the handlebars do not
contact the gas tank or any
other part of the machine
when turned fully to the left or
right.
4. Torque the front two bolts to
14-17 N-m, then torque the rear
two bolts. A gap of up to 3 mm
will remain at the rear bolts.
Rear Spring Adjustment
The rear shock absorber spring
is adjusted by rotating the
adjuster either clockwise or
counterclockwise to increase
or decrease spring tension.
WARNING
Improper adjustment of the handlebars or incorrect torquing of the adjuster
block tightening bolts can cause limited steering or loosening of the
handlebars, resulting in loss of control. Follow the adjustment procedures
exactly, or see your Polaris dealer for service.
14-17 N-m
Adjuster
90
MAINTENANCE
Side Panel Removal
1. Remove the seat.
2. Grasp the rear of the side panel
near the rear cab.
3. With a firm motion, pull the
panel outward to disengage the
side panel from the grommet.
4. Pull the panel downward and
rearward to remove it.
Footwell Removal
1. Remove the four screws on
the bottom of the footwell.
2. Use a flat screwdriver or
sidecutters to remove the
plastic rivets securing the
footwell to the fenders.
3. Remove the footwell.
Screws
Rivets
91
MAINTENANCE
Throttle Cable Freeplay
Adjust throttle cable freeplay at the handlebar.
1. Locate the throttle cable adjuster
at the handlebar.
2. Squeeze the end of the rub-
ber boot and slide it far
enough to expose the end of
the inline cable adjuster.
3. Loosen the adjuster lock nut.
4. Rotate the boot to turn the
adjuster until 1.6-3.2 mm of
freeplay is achieved at the
thumb lever.
NOTE: Move the throttle lever
back and forth while
adjusting.
5. Tighten the lock nut.
6. Squeeze the end of the
rubber boot and slide it
over the cable adjuster to
its original position.
NOTE: Engine RPM should not increase when steering is turned full left or
right. Readjust cable freeplay if this occurs.
Boot
Lock Nut
Adjuster
1.6-3.2 mm
92
MAINTENANCE
Tires
Refer to the specifications section beginning on page 122 for recom-
mended tire type, size and pressure.
Tire Tread Depth
Always replace tires
when tread depth is
worn to 3 mm or less.
Front Wheel Hub Tightening
Front wheel bearing tightness and spindle nut retention are critical com-
ponent operations. All service must be performed by your authorized
Polaris dealer.
Wheel Nut Torque Specifications
Check the wheel nut torques occasionally and when they've been loos-
ened for maintenance service.
WARNING
Operating your vehicle with worn tires, improperly inflated tires, non-standard
tires or improperly installed tires will affect vehicle handling and could cause
an accident.
• Maintain proper tire pressure as described on the decal on your vehicle
and in the specifications section of the owner's manual.
• Use only original equipment size and type when replacing tires.
• Make sure the wheels are installed properly.
• Replace tires when the tread depth measures 3 mm or less.
Nut Type Nut Torque
Lug Nut 122 Nm
2-Piece Flange Nut 37 Nm
3 mm
93
MAINTENANCE
Tires
Always use original equipment size and type when replacing tires. Install wheels
properly.
Wheel Removal/Installation
1. Position the vehicle on a level
surface.
2. Place the transmission in PARK.
3. Loosen the wheel nuts
slightly.
4. Place a suitable stand under
the footrest frame to raise the
wheel slightly off the ground.
5. Remove the wheel nuts.
6. Remove the wheel.
7. Place the wheel on the hub.
8. Install the wheel nuts finger
tight.
9. Lower the vehicle to the
ground.
10. Torque the wheel nuts to
specification. See torque
chart on page 92.
94
MAINTENANCE
Air Filter
Always clean and replace the air and breather filters at the intervals out-
lined in the Periodic Maintenance Chart beginning on page 59.
1. Position the vehicle on a level
surface.
2. Place the transmission in PARK.
3. Remove the seat.
4. Release the air box
cover clips.
5. Remove the air
box cover.
6. Loosen the hose
clamp.
7. Remove the filter.
8. Remove the pre-filter
from the filter.
9. Wash the pre-filter in soapy water. Rinse and air dry.
NOTE: Replace the filter if needed.
10. Reverse the steps to reinstall all components.
Main Filter
Pre-Filter
95
MAINTENANCE
Breather Filter/Hose (500 EFI)
The breather filter is on the hose between the engine and air box.
1. Remove the left side panel.
See page 90.
2. Remove the hose clamps from
the filter and pull the filter out
of the hoses.
3. Inspect the filter for debris.
Blow gently through the filter
in the direction of the arrow to
check for clogging. Replace a
damaged or clogged filter.
4. Check the hoses for cracks, deterioration, abrasion, or leaks.
Replace as needed.
5. Reinstall the filter and hose clamps.
NOTE: The filter is effective with the arrow pointing in either direction.
Operation of your vehicle without a breather filter can cause engine damage.
Breather
Filter
96
MAINTENANCE
Lights
Headlight Beam Adjustment
The headlight beam can be adjusted slightly upward or downward.
1. Position the vehicle on a level
surface. The headlight should be
approximately 7.6 m from a wall.
2. Place the transmission in PARK.
3. Measure the distance from the floor to the center of the headlight
and make a mark on the wall at the same height.
NOTE: Include rider weight on the seat when measuring.
4. Start the engine.Turn the headlight switch to high beam.
5. Observe the headlight aim on the wall. The most intense part of the
headlight beam should be 5 cm below the mark on the wall.
6. Tighten or loosen the lower headlight screws to adjust the beam
upward or downward or to the left or right.
7.6 m
5 cm
X
X
97
MAINTENANCE
Lights
Headlight/Position Light Lamp Replacement
When servicing a halogen lamp, do
not touch the lamp with bare fingers.
Oil from your skin leaves a residue,
causing a hot spot that will shorten
the life of the lamp. Hold the plastic
part of the lamp.
1. Place the transmission in PARK.
2. Open the front rack cover.
3. Remove the plug at the back of the
headlight.
4. Pull the harness plug to disconnect
it from the back of the headlight.
5. Position light: Rotate the socket to
remove it. Go to step 6.
Headlamp: Reach under the
bumper and remove the rubber
cover from the back of the
headlight. Turn the collar counter-
clockwise and carefully remove
the collar and socket.
6. Remove the lamp. Apply dielectric
grease to the socket and install a
new lamp.
7. Reverse all steps to reassemble the
headlight.
WARNING
Poor lighting can result in loss of control or an accident. Lights become dirty
during normal operation. Wash the headlights and taillights frequently.
Hot components can cause serious burns to skin. Do not service the
headlamps until they've cooled.
Position Light
Collar
Socket
Headlamp
98
MAINTENANCE
Lights
Taillight Lamp Replacement
1. Place the transmission in
PARK.
2. Rotate the taillight socket
counterclockwise to remove it.
3. Remove the lamp.
4. Apply dielectric grease to the
socket.
5. Install the new lamp. Test the lamp for proper operation.
6. Reinstall all components in reverse order.
Front Turn Signal Lamp Replacement
1. Place the transmission in
PARK.
2. Remove the lens attachment
screw.
3. Rotate the lamp to remove it.
4. Install the new lamp.
5. Reinstall the lens.
Rear Turn Signal Lamp Replacement
1. Place the transmission in PARK.
2. Rotate the turn signal socket
counterclockwise to remove it.
3. Remove the lamp.
4. Apply dielectric grease to the
socket.
5. Install the new lamp. Test the lamp for proper operation.
6. Reinstall all components in reverse order.
Screw
Lamp
99
MAINTENANCE
Fuse Replacement
If the engine stops or will not start,
or if you experience other electrical
failures, a fuse may need replace-
ment.
NOTE: Spare fuses are provided in a
compartment on the top of the
access door.
1. Open the front box cover and
pull open the access door.
2. Remove the suspect fuse from
the fuse panel. If the fuse is
blown, install a new fuse with
the same amperage.
3. Secure the access door.
4. Secure the box cover.
Fuse Panel
Fuses
5or61520 20
100
MAINTENANCE
Spark Plugs
Spark Plug Recommendations
Refer to the specifications section beginning on page 122 for the recom-
mended spark plug type and gap for your vehicle. Torque spark plugs to
specification.
Spark Plug Inspection
Spark plug condition is indicative of engine operation. Check the spark
plug firing end condition after the engine has been warmed up and the
vehicle has been driven at higher speeds. Immediately check the spark
plug for correct color. See page 101.
Normal Spark Plug
The normal insulator tip is tan or brown. There will be few combustion
deposits. The electrodes are not burned or eroded. This indicates the
proper type and heat range for the engine and the service.
NOTE: The tip should not be white. A white insulator tip indicates overheating,
caused by use of an improper spark plug or incorrect throttle body
adjustments.
Wet Fouled Spark Plug
The wet fouled insulator tip is black. A damp oil film covers the firing
end. There may be a carbon layer over the entire nose. Generally, the
electrodes are not worn. General causes of fouling are excessive oil con-
sumption or incorrect throttle body adjustments.
Plug Condition Torque Specification
New Spark Plug 12-15 N-m
Previously Installed Spark Plug 23-27 N-m
101
MAINTENANCE
Spark Plugs
Spark Plug Removal
1. Remove the left side panel.
See page 90.
2. Remove the spark plug cap.
3. Use the spark plug wrench
to remove the spark plug.
Turn the plug
counterclockwise to
remove it.
4. Inspect the electrodes for
wear and carbon buildup.
Replace worn or fouled
plugs. Verify that the gap is
at specification before
installation.
5. Reinstall the spark plug.
Torque to specification. See
page 100.
6. Reinstall the spark plug cap.
102
MAINTENANCE
Vehicle Immersion
If your vehicle has been totally submerged in water and it's impossible
to have it serviced before further operation, perform the following pro-
cedure.
If the vehicle stops while fully submerged, major engine damage can result if the
machine is not thoroughly inspected. Take the vehicle to your dealer before
starting the engine.
1. Move the vehicle out of the
water.
2. Remove the spark plug.
3. Drain any water found in the air box.
103
MAINTENANCE
Vehicle Immersion
4. Turn the ignition key past the
POSITION LIGHTS position to
engage the starter. Engage the
starter for only 2-3 seconds.
5. Dry the spark plug. Reinstall the
plug or install a new plug.
6. Torque to specification. See page
100.
7. Attempt to start the engine. If
necessary, repeat the drying
procedure.
8. Have the vehicle serviced by
your dealer promptly, whether
you succeed in starting it or not.
NOTE: If water has been ingested into the PVT, follow the procedure on page
107 for drying out the PVT.
104
MAINTENANCE
Spark Arrestor
Occasionally, the spark arrestor may accumulate carbon, which can
restrict the exhaust if left unattended. Purge the spark arrestor.
1. Position the vehicle on a level
surface.
2. Place the transmission in PARK.
3. Remove the arrestor
clean-out plug from the
bottom of the muffler.
4. Start the engine.
5. Quickly squeeze and
release the throttle lever
several times to purge car-
bon from the system.
WARNING
Allow components to cool sufficiently before servicing. The exhaust system
can get extremely hot. Never run the engine in an enclosed area or indoors.
Exhaust contains poisonous carbon monoxide gas. Never go under the
vehicle while it's inclined.
Remove any combustible materials from the area. Wear eye protection and
leather work gloves. Do not stand behind or in front of the vehicle while
purging.
105
MAINTENANCE
Spark Arrestor
6. If carbon comes out of the
exhaust, cover or plug the exhaust
outlet. Wear protective gloves.
7. Lightly tap on the exhaust pipe
with a rubber mallet while repeat-
ing step 5.
8. If particles are still suspected to
be in the muffler, elevate the
rear of the vehicle 30 cm
higher than the front. Block the
wheels.
9. Place the transmission in
PARK. Repeat steps 5 to 7 until
no more particles are expelled.
10. Stop the engine. Allow the arrestor to cool.
11. Reinstall the arrestor plug and remove the exhaust outlet cover or
plug.
30 cm
106
MAINTENANCE
PVT System
Do not modify any component of the PVT system. Doing so may reduce its
strength so that a failure may occur at a high speed. The PVT system has been
precision balanced. Any modification will cause the system to be out of balance,
creating vibration and additional loads on components.
The PVT system rotates at high speeds, creating large amounts of force on
clutch components. Extensive engineering and testing has been conducted to
ensure the safety of this product. However, as the owner, you have the following
responsibilities to make sure this system remains safe:
• Always follow all recommended maintenance procedures. See your dealer as
outlined in the owner's manual.
• This PVT system is intended for use on Polaris products only. Do not install it
in any other product.
• Always make sure the PVT housing is securely in place during operation.
107
MAINTENANCE
PVT System
PVT Drying
There may be some instances when water is accidently ingested into the
PVT system. Dry it out before operating.
1. Position the vehicle on a level
surface.
2. Place the transmission in PARK.
3. Remove the drain
plug. Allow the water
to drain completely.
Reinstall the drain
plug.
4. Start the engine.
5. Apply varying throttle for 10-15 seconds to expel the moisture and
air-dry the belt and clutches.
NOTE: Do not hold the throttle wide open for more than 10 seconds.
6. Allow the engine RPM to settle to idle speed, then shift the trans-
mission to the lowest available range.
7. Test for belt slippage. If the belt slips, repeat the process.
8. Take the vehicle to your dealer for service as soon as possible.
108
MAINTENANCE
Recoil Housing (if equipped)
Always drain the recoil housing
after operating the vehicle in wet
conditions. Drain the housing before
storing the vehicle. Make sure the
housing is completely dry before
reinstalling the drain plug.
1. Place the transmission in PARK.
2. Stop the engine.
3. Remove the drain screw on the
bottom of the recoil housing.
4. Allow the housing to drain com-
pletely.
5. Reinstall the drain screw.
NOTE: Do not open the crankcase drain
unless the engine has ingested
water. On 4-cycle engines, some
engine oil will be lost if the crank-
case drain is opened.
Recoil Housing
109
MAINTENANCE
Battery
Your vehicle may have either a sealed battery, which requires little
maintenance, or a conventional battery. A sealed battery can be identi-
fied by its flat covers on the top of the battery. A conventional battery
has six filler caps on the top of the battery.
Conventional Battery
Always keep battery terminals and connections free of corrosion. If
cleaning is necessary, remove corrosion with a stiff wire brush. Wash
with a solution of one tablespoon baking soda and one cup water. Rinse
well with tap water and dry off with clean shop towels. Coat the termi-
nals with dielectric grease or petroleum jelly. Be careful not to allow
cleaning solution or tap water into a conventional battery.
WARNING
Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can
result from contact with skin, eyes or clothing.
Antidote:
External: Flush with water.
Internal: Drink large quantities of water or milk. Follow with milk of magnesia,
beaten egg, or vegetable oil. Call physician immediately.
Eyes: Flush with water for 15 minutes and get prompt medical attention.
Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc.
away. Ventilate when charging or using in an enclosed space. Always shield
eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN.
110
MAINTENANCE
Battery
Battery Removal
1. Place the transmission in PARK.
2. Remove the seat.
3. Disconnect the battery hold-down strap.
4. Remove the battery cover (if equipped).
5. On conventional batteries, remove the battery vent tube.
6. Disconnect the black (negative) battery cable first.
7. Disconnect the red (positive) battery cable last.
8. Lift the battery out of the vehicle. Be careful not to tip a conven-
tional battery sideways, which could spill electrolyte.
NOTE: If electrolyte spills, immediately wash it off with a solution of one table-
spoon baking soda and one cup water to prevent damage to the vehi-
cle.
WARNING
Improperly connecting or disconnecting battery cables can result in an
explosion and cause serious injury or death. When removing the battery,
always disconnect the negative (black) cable first. When reinstalling the
battery, always connect the negative (black) cable last.
111
MAINTENANCE
Battery
Battery Installation
1. Ensure that the battery is fully charged.
2. Place the battery in the battery holder.
3. With conventional batteries, install the battery vent tube (sealed bat-
teries do not have a vent tube).
NOTE: The vent tube must be free of obstructions and securely installed.
Route the tube away from the frame and vehicle body to prevent con-
tact with electrolyte.
4. On conventional batteries, coat the terminals with dielectric grease
or petroleum jelly.
5. Connect and tighten the red (positive) cable first.
6. Connect and tighten the black (negative) cable last.
7. Secure the battery hold-down strap.
8. Reinstall the battery cover (if equipped).
9. Verify that cables are properly routed.
NOTE: Cables should be safely tucked away at the front and rear of the bat-
tery.
10. Reinstall the seat.
WARNING
Battery gases could accumulate in an improperly installed vent tube and
cause an explosion, resulting in serious injury or death. Always ensure that
the vent tube is free of obstructions and is securely installed as
recommended.
112
MAINTENANCE
Battery
Battery Storage
Whenever the vehicle is not used for a period of three months or more,
remove the battery from the vehicle, ensure that it's fully charged, and
store it out of the sun in a cool, dry place. Check battery voltage each
month during storage and recharge as needed to maintain a full charge.
NOTE: Battery charge can be maintained by using a Polaris Battery Tender
charger or by charging about once a month to make up for normal self-
discharge. Battery Tender can be left connected during the storage
period, and will automatically charge the battery if the voltage drops
below a pre-determined point. See page 126 for the part numbers of
Polaris products.
Battery Fluid (Conventional Battery)
Check the battery fluid level
often. Maintain the fluid level
between the upper and lower
level marks.
Add only distilled water. Tap
water contains minerals that are
harmful to a battery.
Lower
Mark
Upper
Mark
113
MAINTENANCE
Battery
Battery Charging (Conventional Battery)
1. Remove the battery from the vehicle to prevent damage from leak-
ing or spilled electrolyte during charging. See page 110.
2. Charge the battery with a charging output no larger than 1/10 of the
battery’s amp/hr rating. Charge as needed to raise the specific grav-
ity to 1.270 or greater.
3. Reinstall the battery. See page 111. Make sure the positive terminal
is toward the front of the vehicle.
Battery Charging (Sealed Battery)
The following battery charging instructions apply only to the installa-
tion of a sealed battery. Read all instructions before proceeding with the
installation of this battery.
The sealed battery is already filled with electrolyte and has been sealed
and fully charged at the factory. Never pry the sealing strip off or add
any other fluid to this battery.
The single most important thing about maintaining a sealed battery is to
keep it fully charged. Since the battery is sealed and the sealing strip
cannot be removed, you must use a voltmeter or multimeter to measure
DC voltage.
114
MAINTENANCE
Battery
Battery Charging (Sealed Battery)
For a refresh charge, follow all instructions carefully.
1. Check the battery voltage with a voltmeter or multimeter. A fully
charged battery will register 12.8 V or higher.
2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps
or less until battery voltage is 12.8 or greater.
NOTE: When using an automatic charger, refer to the charger manufacturer's
instructions for recharging. When using a constant current charger,
use the following guidelines for recharging.
NOTE: Always verify battery condition before and 1-2 hours after the end of
charging.
WARNING
An overheated battery may explode, causing severe injury or death. Always
watch charging times carefully. Stop charging if the battery becomes very
warm to the touch. Allow it to cool before resuming charging.
State of
Charge
Voltage Action
Charge Time
(Using constant current
charger @ standard amps
specified on top of battery)
100% 12.8-13.0 volts None, check at 3
mos. from date of
manufacture
None required
75%-100% 12.5-12.8 volts May need slight
charge, if no
charge given,
check in 3 months
3-6 hours
50%-75% 12.0-12.5 volts Needs charge 5-11 hours
25%-50% 11.5-12.0 volts Needs charge At least 13 hours,
verify state of charge
0%-25% 11.5 volts or less Needs charge with
desulfating charger
At least 20 hours
115
MAINTENANCE
Cleaning and Storage
Washing the Vehicle
Keeping your Polaris vehicle clean will not only improve its appearance
but it can also extend the life of various components.
High water pressure may damage components. Polaris recommends
washing the vehicle by hand or with a garden hose, using mild soap.
Certain products, including insect repellents and chemicals, will damage
plastic surfaces. Do not allow these types of products to contact the
vehicle.
1. Use a professional-type washing cloth, cleaning the upper body first
and the lower parts last.
2. Rinse with clean water frequently.
3. Dry surfaces with a chamois to prevent water spots.
Washing Tips
• Avoid the use of harsh cleaners, which can scratch the finish.
• Do not use a power washer to clean the vehicle.
• Do not use medium to heavy duty compounds on the finish.
• Always use clean cloths and pads for cleaning and polishing. Old or
reused cloths and pads may contain dirt particles that will scratch the
finish.
116
MAINTENANCE
Cleaning and Storage
Washing the Vehicle
If a high pressure water system is used for cleaning (not recommended),
exercise extreme caution. The water may damage components and could
remove paint and decals. Avoid directing the water stream at the follow-
ing items:
• Wheel bearings
• Transmission seals
•Brakes
• Cab and body panels
• Labels and decals
NOTE: If warning and safety labels are damaged, contact your Polaris dealer
for free replacement.
Grease all zerk fittings immediately after washing. Allow the engine to
run for a while to evaporate any water that may have entered the engine
or exhaust system.
Polishing the Vehicle
Polaris recommends the use of common household aerosol furniture
polish for polishing the finish on your Polaris vehicle. Follow the
instructions on the container.
Polishing Tips
• Avoid the use of automotive products, some of which can scratch the
finish of your vehicle.
• Always use clean cloths and pads for cleaning and polishing. Old or
reused cloths and pads may contain dirt particles that will scratch the
finish.
117
MAINTENANCE
Cleaning and Storage
Chrome Wheel Care (if equipped)
Proper maintenance will protect chrome wheels from corrosion, pre-
serve wheel life and ensure a "like new" appearance for many years.
NOTE: Chrome wheels exposed to road salt (or salt in the air in coastal areas)
are more susceptible to corrosion if not properly cleaned. Clean
chrome wheels more often if they're exposed to salt or other corrosive
elements.
1. Wash chrome wheels frequently. Use a mild detergent. Never use
abrasive cleaners on plated or painted surfaces.
2. Rinse well with clear water. Soap, detergents, salt, dirt, mud and
other elements can cause corrosion.
3. Polish the clean chrome wheels periodically. Use an automotive
grade chrome polish.
4. Routinely and liberally apply a weather resistant wax to each pol-
ished chrome wheel. Choose a product suitable for chrome finishes.
Read and follow the product labels and instructions.
Removing Corrosion
If light rust is found on the chrome finish, use steel wool (#0000-OTT
grade) to remove it. Gently rub the affected areas with the steel wool
until the corrosion has been removed. Clean and polish the wheel as out-
lined above.
118
MAINTENANCE
Cleaning and Storage
Storage Tips
Starting the engine during the storage period will disturb the protective film
created by fogging and damage could occur. Never start the engine during the
storage period.
Clean the Exterior
Make any necessary repairs and clean the vehicle as recommended. See
page 115.
Stabilize the Fuel
1. Fill the fuel tank.
2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer.
Follow the instructions on the container for the recommended
amount.
NOTE: Carbon Clean removes water from fuel systems, stabilizes fuel and
removes carbon deposits from pistons, rings, valves and exhaust sys-
tems.
3. Allow the engine to run for 15-20 minutes to allow the stabilizer to
disperse through the entire fuel delivery system.
Oil and Filter
Change the oil and filter. See page 67.
Air Filter / Air Box
1. Inspect and clean (or replace) the pre-cleaner and air filter.
2. Clean the air box.
3. Clean or replace the breather filter.
4. Drain the sediment tube.
Recoil Housing (if equipped)
1. Drain the recoil housing. See page 108.
119
MAINTENANCE
Cleaning and Storage
Storage Tips
Fluid Levels
Inspect the fluid levels. Change fluids as recommended in the Periodic
Maintenance Chart beginning on page 59.
• Demand drive unit (front gearcase)
• Transmission
• Rear gearcase (if equipped)
• Brake fluid (change every two years and any time the fluid looks dark
or contaminated)
• Coolant (test strength)
Fog the Engine
1. Treat the fuel system with Polaris Carbon Clean. See page 118.
2. Remove the spark plug. Pour 30-45 ml of engine oil into the plug
holes.
3. Reinstall the spark plugs. Torque to specification.
4. Apply dielectric grease to the inside of each spark plug cap. Rein-
stall the caps.
5. Turn the engine over several times (using the recoil starter, if
equipped). Oil will be forced in and around the piston rings and ring
lands, coating the cylinder with a protective film of fresh oil.
6. If Polaris fuel system additive is not used, the fuel tank, fuel lines,
and injectors should be completely drained of gasoline.
120
MAINTENANCE
Cleaning and Storage
Storage Tips
Inspect and Lubricate
Inspect all cables and lubricate all areas of the vehicle as recommended
in the Periodic Maintenance Chart beginning on page 59.
Battery Storage
See pages 112-113 for storage and charging procedures.
Storage Area/Covers
1. Set the tire pressure and safely support the vehicle with the tires
slightly off the ground.
2. Be sure the storage area is well ventilated.
3. Cover the vehicle with a genuine Polaris cover. Do not use plastic or
coated materials. They do not allow enough ventilation to prevent
condensation, and may promote corrosion and oxidation.
Accessories
Auxiliary power outlets provide 12-volt power for operating accesso-
ries. Accessory outlets are available for all models. Polaris also has a
wide range of additional accessories available for your vehicle. Always
install accessories that are approved for Quadricycle use. Please see
your Polaris dealer.
121
MAINTENANCE
Transporting the Vehicle
Follow these procedures when transporting the vehicle.
1. Stop the engine.
2. Place the transmission in PARK.
3. Secure the fuel cap, oil cap and
seat.
4. Remove the key to prevent loss during
transporting.
5. Always tie the frame of the Quadricycle to the transporting unit
securely with suitable straps or rope. Do not attach tie straps to the
front A-arm bolt pockets.
Towing a Disabled Vehicle
If towing the vehicle is necessary, shift the transmission into neutral for
better mobility and to prevent damage to the belt.
Always attach the tow rope to the frame of the Quadricycle.
122
SPECIFICATIONS
Sportsman 500 EFI International
Gross Vehicle Weight 1200 lbs. (544 kg)
Dry Weight 745 lbs. (338 kg)
Fuel Capacity 4.13 gal. (15.6 l)
Engine Oil Capacity 2 qts. (1.9 l)
Coolant Capacity 2.25 qts. (2.1 l)
Demand Drive Fluid Capacity 6 oz. (175 ml)
Transmission Oil Capacity 32 oz. (948 ml)
Front Rack/Storage Box Capacity 90 lbs. (41 kg)
Rear Rack/Storage Box Capacity 180 lbs. (81.6 kg)
Receiver Hitch Tongue Capacity
(Off-road use only)
120 lbs. (55 kg) (Rear rack capacity and tongue
weight not to exceed 180 lbs./81.6 kg)
Receiver Hitch Towing Capacity 1225 lbs. (557 kg)
Overall Length 83 in. (211 cm)
Overall Width 48 in. (122 cm)
Overall Height 48 in. (122 cm)
Wheelbase 50.5 in. (128.3 cm)
Ground Clearance 11.25 in. (28.5 cm)
Minimum Turning Radius 65 in. (165 cm) unloaded
Engine EH50PLE
Displacement 498 cc
Bore x Stroke 92 x 75
Alternator Output 350 w
Compression Ratio 10.2:1
Fuel System Electronic Fuel Injection
Ignition System Electronic Ignition
Ignition Timing 13 +/- 3 BTDC @ 1150 RPM, engine warm
Spark Plug / Gap NGK BKR6E / .035 in. (0.9 mm)
Lubrication System Dry Sump
Driving System Type Automatic PVT (Polaris Variable Transmission)
Front Suspension MacPherson strut with 8.2" (21 cm) travel
Rear Suspension Progressive rate with 9.5" (24 cm) travel
123
SPECIFICATIONS
Clutching (EBS Models)
NOTE: *EBS models require no helix/spring adjustment
Sportsman 500 EFI International
Shift Type Side Lever (H/L/N/R/P)
Gear Reduction, Low 23.91:1
Gear Reduction, Reverse 16.30:1
Gear Reduction, Forward 10.49:1
Drive Ratio, Front 3.82:1
Tires/Pressure, Front 25x8-12 / 5 psi
Tires/Pressure, Rear 25x12.5-12 / 5 psi
Brake, Hand All-wheel hydraulic disc
Brake, Foot All-wheel hydraulic disc
Brake, Parking Transmission park lock and hydraulic lock, all
wheel
Headlight 2 Hi/Lo beam on bumper (37.5 watt)
Taillights 8.26 watts
Brake Light 26.9 watts
Instrument Cluster LCD
Altitude Shift
Weight
Drive Clutch
Spring
Driven
Clutch
Spring
Helix*
Meters
(Feet)
0-1800
(0-6000)
10 WH
PN 5630710
Blue/Green
PN 7041157
White/Yellow
PN 7041635
EBS
PN 5131674
1800-3700
(6000-12000)
10 RH
PN 5630709
Blue/Green
PN 7041157
White/Yellow
PN 7041635
EBS
PN 5131674
124
SPECIFICATIONS
Sportsman 800 EFI International
Gross Vehicle Weight 1240 lbs. (563 kg)
Dry Weight 770 lbs. (349 kg)
Fuel Capacity 4.13 gal. (15.6 l)
Engine Oil Capacity 2 qts. (1.9 l)
Coolant Capacity 3.2 qts. (3 l)
Rear Gearcase Oil Capacity 5 oz. (150 ml)
Demand Drive Fluid Capacity 6 oz. (175 ml)
Transmission Oil Capacity 15 oz. (450 ml)
Front Rack/Storage Box Capacity 100 lbs. (45 kg)
Rear Rack Capacity 200 lbs. (91 kg)
Receiver Hitch Tongue Capacity
(Off-road use only)
150 lbs. (68 kg) (Rear rack capacity and tongue
weight not to exceed 200 lbs./91 kg)
Receiver Hitch Towing Capacity 1500 lbs. (682 kg)
Overall Length 83 in. (211 cm)
Overall Width 48 in. (122 cm)
Overall Height 48 in. (122 cm)
Wheelbase 50.75 in. (128.9 cm)
Ground Clearance 11.25 in. (28.5 cm)
Minimum Turning Radius 71.5 in. (182 cm) unloaded
Engine EH0760LE
Displacement 760 cc
Bore x Stroke 80 x 76
Alternator Output 500 Watts @ 3000 rpm
Compression Ratio 10:1
Starting System Electric
Fuel System Electronic Fuel Injection
Ignition System ECU
Ignition Timing 8 BTDC @ 2000 RPM
Spark Plug / Gap RC7YC / .035 in. (0.9 mm)
Lubrication System Pressurized Wet Sump
Driving System Type Automatic PVT (Polaris Variable Transmission)
Front Suspension MacPherson strut with 8.2" (21 cm) travel
Rear Suspension Progressive rate with 9.5" (24 cm) travel
125
SPECIFICATIONS
Clutching (EBS Models)
NOTE: *EBS models require no helix/spring adjustment
Sportsman 800 EFI International
Transmission Automatic PVT w/E-Z Shift H/L/N/R/P
Gear Reduction, Low 7.49:1
Gear Reduction, Reverse 5.11:1
Gear Reduction, High 2.70:1
Drive Ratio, Front 3.82:1
Drive Ratio, Final 3.10:1
Tires/Pressure, Front 25x8-12 / 5 psi
Tires/Pressure, Rear 25x12.5-12 / 5 psi
Brake, Hand All-wheel hydraulic disc
Brake, Foot All-wheel hydraulic disc
Brake, Parking Transmission park lock and hydraulic lock, all
wheel
Headlight 2 Hi/Lo beam on bumper (37.5 watt)
Taillights 8.26 watts
Brake Light 26.9 watts
Instrument Cluster LCD
Altitude Shift
Weight
Drive Clutch
Spring
Driven
Clutch
Spring
Helix*
Meters
(Feet)
0-1800
(0-6000)
20-62
PN 5631700
Blue/Green
PN 7041157
Orange
PN 3234233
EBS
PN 3234234
1800-3700
(6000-12000)
20-58
PN 5631216
Blue/Green
PN 7041157
Orange
PN 3234233
EBS
PN 3234234
126
POLARIS PRODUCTS
Part Number Description
Engine Lubricant
2870791 Fogging Oil (12 oz. Aerosol)
2871281 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (.95 l)
2871844 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (3.8 l)
Gearcase / Transmission Lubricants
2873602 Premium AGL Synthetic Gearcase Lubricant (.95 l)
2873603 Premium AGL Synthetic Gearcase Lube (3.8 l)
2871653 Premium ATV Angle Drive Fluid (237 ml)
2872276 Premium ATV Angle Drive Fluid (9.5 l)
2870465 Pump for 3.8 liter jug
2871654 Premium Demand Drive Hub Fluid (237 ml)
2872277 Premium Demand Drive Hub Fluid (9.5 l)
Coolant
2871323 60/40 Coolant (3.8 l)
2871534 60/40 Coolant (.95 l)
Grease / Specialized Lubricants
2871312 Grease Gun Kit, Premium All Season
2871322 Premium All Season Grease (89 ml cartridge)
2871423 Premium All Season Grease (414 ml cartridge)
2871460 Starter Drive Grease
2871515 Premium U-Joint Lube (89 ml)
2871551 Premium U-Joint Lube (414 ml)
2871329
Dielectric Grease (Nyogel
TM
)
2872073 Chain Lube, Aerosol (185 ml)
2872348 Chain Lube, Aerosol (473 ml)
Additives / Miscellaneous
2872889 Brake and Clutch Cleaner
2871326 Carbon Clean Plus
2870652 Fuel Stabilizer
2872189 DOT4 Brake Fluid
2872893 Engine Degreaser
2871956
Loctite
TM
565 Thread Sealant
2871076
Polaris Battery Tender
TM
Charger
127
TROUBLESHOOTING
Drive Belt Wear/Burn
Possible Cause Solution
Driving onto a pickup or
tall trailer in high range
Use low range.
Starting out going up a
steep incline
Use low range or turn around using the K-turn (see page
26).
Driving at low RPM or
ground speed (3-7 MPH)
Drive at a higher speed or use low range more frequently.
Insufficient warm-up at
low ambient tempera-
tures
Warm the engine at least 5 minutes. With the transmission
in neutral, advance the throttle to about 1/8 throttle in
short bursts, 5 to 7 times. The belt will become more flex-
ible and prevent belt burning.
Slow/easy clutch engage-
ment
Use the throttle quickly and effectively.
Towing/pushing at low
RPM/low ground speed
Use low range only.
Utility use/plowing Use low range only.
Stuck in mud or snow Shift the transmission to low range. Carefully use fast,
aggressive throttle application to engage clutch.
WARNING: Excessive throttle may cause loss of control
and vehicle overturn.
Climbing over large
objects from a stopped
position
Belt slippage from water
or snow ingestion into the
PVT system
Dry out the PVT. See page 107. Inspect clutch seals for
damage if repeated leaking occurs.
Clutch malfunction See your Polaris dealer.
Poor engine performance Check for fouled plugs or foreign material in gas tank or
fuel lines. See your dealer.
Slippage from failure to
warm up belt
Always warm up the belt by operating below 48 km/h for
1.6 km. Operate 8 km or more when temperature is below
freezing.
Wrong or missing belt Install the recommended belt.
Improper break-in Always break in a new belt and/or clutch. See page 54.
128
TROUBLESHOOTING
Engine Does Not Rotate
Engine Rotates, Fails to Start
Engine Backfires
Possible Cause Solution
Low battery voltage Recharge the battery to 12.8 VDC
Loose battery connections Check all connections and tighten
Loose solenoid connections Check all connections and tighten
Possible Cause Solution
Out of fuel Refuel
Clogged fuel filter Replace the filter
Water is present in fuel Drain the fuel system and refuel
Old or non-recommended fuel Replace with fresh recommended fuel
Fouled or defective spark plug(s) Inspect plugs and replace if necessary
No spark to spark plug Inspect plugs, verify stop switch is on
Water or fuel in crankcase Immediately see your Polaris dealer
Low battery voltage Recharge the battery to 12.8 VDC
Mechanical failure See your dealer
Possible Cause Solution
Weak spark from spark plug Inspect, clean and/or replace spark
plug(s)
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
Old or non-recommended fuel
Loose ignition connections Check all connections and tighten
Water present in fuel Replace with fresh recommended fuel
Incorrectly installed spark plug wires See your dealer
Incorrect ignition timing See your dealer
Mechanical failure See your dealer
129
TROUBLESHOOTING
Engine Pings or Knocks
Engine Runs Irregularly, Stalls or Misfires
Possible Cause Solution
Poor quality or low octane fuel Replace with recommended fuel
Incorrect ignition timing See your dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
Possible Cause Solution
Fouled or defective spark plug(s) Inspect, clean and/or replace spark
plug(s)
Worn or defective spark plug wires See your dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
Loose ignition connections Check all connections and tighten
Water present in fuel Replace with new fuel
Low battery voltage Recharge battery to 12.8 VDC
Kinked or plugged fuel tank vent line Inspect and replace
Incorrect fuel Replace with recommended fuel
Clogged air filter Inspect and clean or replace
Reverse speed limiter malfunction See your dealer
Electronic throttle control malfunction See your dealer
Other mechanical failure See your dealer
Possible Lean Fuel Cause Solution
Low or contaminated fuel Add or change fuel, clean the fuel system
Low octane fuel Replace with recommended fuel
Clogged fuel filter Replace filter
Kinked or plugged fuel vent line Inspect and replace (if equipped)
Possible Rich Fuel Cause Solution
Fuel is very high octane Replace with lower octane fuel
Stopping/starting without adequate
warm-up
Allow engine to warm up before operat-
ing and/or stopping
Incorrect fuel Replace with recommended fuel
Clogged air filter Inspect and clean or replace
130
TROUBLESHOOTING
Engine Stops or Loses Power
Engine Overheating
Possible Cause Solution
Out of fuel Refuel, cycle key to ON position three
times for 5 seconds each, then start
Kinked or plugged fuel vent line Inspect and replace (if equipped)
Water is present in fuel Replace with fresh recommended fuel
Old or non-recommended fuel Replace with fresh recommended fuel
Fouled or defective spark plug(s) Inspect, clean and/or replace spark
plug(s)
Worn or defective spark plug wires See your dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plug
Loose ignition connections Check all connections and tighten
Low battery voltage Recharge the battery to 12.8 VDC
Clogged air filter Inspect and clean or replace
Reverse speed limiter malfunction See your dealer
Electronic throttle control malfunction See your dealer
Other mechanical failure See your dealer
Overheated engine Clean radiator screen and core, clean
engine exterior, see your dealer
Possible Cause Solution
Debris lodged in screen Remove and clean the screen. Pull on the
top portion of the screen, then remove the
lower portion.
Plugged Radiator Use a garden hose to flush any debris
from the radiator fins. NOTE: High
pressure washers can deform the radiator
fins and reduce cooling efficiency.
131
WARRANTY
LIMITED WARRANTY
Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a TWO YEAR
LIMITED WARRANTY on all components of the Polaris Quadricycle against defects in
material or workmanship. This warranty covers the parts and labor charges for repair or
replacement of defective parts which are covered by this warranty. This warranty begins
on the date of purchase. This warranty is transferable to another consumer during the
warranty period through a Polaris dealer.
REGISTRATION
At the time of sale, the Warranty Registration Form must be completed by your dealer
and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will
record the registration for warranty. THE PURCHASER MUST COMPLETE A
QUADRICYCLE SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN
ORDER TO HAVE VALID WARRANTY ON THE QUADRICYCLE. No verification
of registration will be sent to the purchaser as the copy of the Warranty Registration
Form will be the warranty entitlement. If you have not signed the original registration
and received the "customer copy", please contact your dealer immediately. NO WAR-
RANTY COVERAGE WILL BE ALLOWED UNLESS YOUR QUADRICYCLE IS
REGISTERED WITH POLARIS.
Initial dealer preparation and set-up of your vehicle is very important in ensuring trou-
ble-free operation. Purchasing a machine in the crate or without proper dealer set-up will
void your warranty coverage.
132
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 Quadricycle
that has been altered structurally, modified, neglected, improperly maintained, used for
racing, or used for purposes other than for which it was manufactured, or for any dam-
ages which occur during trailer transit or as a result of unauthorized service or the use of
unauthorized parts. In addition, this warranty does not cover physical damage to paint or
finish, stress cracks, tearing or puncturing of upholstery material, corrosion, or defects in
parts, components or the vehicle due to fire, explosions or any other cause beyond
Polaris' control.
This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that
are not compatible with the Quadricycle. The exclusive remedy for breach of this war-
ranty shall be, at Polaris' exclusive option, repair or replacement of any defective materi-
als, or components or products. THE REMEDIES SET FORTH IN THIS WARRANTY
ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF
THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON
FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY
DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR-
RANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR
OTHERWISE. Some states do not permit the exclusion or limitation of incidental or
consequential damages or implied warranties, so the above limitations or exclusions
may not apply to you if inconsistent with controlling state law.
133
WARRANTY
LIMITATIONS OF WARRANTIES AND REMEDIES
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-
TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE TWO
YEAR WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS
WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limi-
tations on how long an implied warranty lasts, so the above limitation may not apply to
you if inconsistent with controlling state law.
HOW TO OBTAIN WARRANTY SERVICE
If your Quadricycle requires warranty service, you must take it to a Polaris dealer autho-
rized to repair Polaris Quadricycles. When requesting warranty service you must present
your copy of the Warranty Registration form to the dealer. (THE COST OF TRANS-
PORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). Polaris
suggests that you use your original selling dealer; however, you may use any Polaris
Servicing Dealer to perform warranty service.
Please work with your dealer to resolve any warranty issues. Should your dealer require
any additional assistance they will contact the appropriate personnel at Polaris.
This warranty gives you specific legal rights, and you may also have other rights which
vary from state to state.
If any of the above terms are void because of state or federal law, all other warranty
terms will remain in effect.
134
MAINTENANCE LOG
Present this section of your manual to your dealer each time your vehicle is serviced.
This will provide you and future owners with an accurate log of maintenance and ser-
vices performed.
DATE KILOMETERS
OR HOURS
TECHNICIAN SERVICE PERFORMED / COMMENTS
135
MAINTENANCE LOG
DATE KILOMETERS
OR HOURS
TECHNICIAN SERVICE PERFORMED / COMMENTS
136
MAINTENANCE LOG
DATE KILOMETERS
OR HOURS
TECHNICIAN SERVICE PERFORMED / COMMENTS
137
INDEX
A
Accessories . . . . . . . . . . . . . . . . . . . 120
Age Restrictions . . . . . . . . . . . . . . . . . 6
Air Filter . . . . . . . . . . . . . . . . . . . . . . 94
All Wheel Drive Switch . . . . . . . . . . 36
All Wheel Drive System . . . . . . . . . . 44
AWD System . . . . . . . . . . . . . . . . . . 44
B
Battery
Charging (Conventional) . . . . 113
Charging (Sealed) . . . . . . 113-114
Conventional. . . . . . . . . . . . . . 109
Fluid (Conventional Battery) . 112
Installation . . . . . . . . . . . . . . . 111
Removal . . . . . . . . . . . . . . . . . 110
Storage . . . . . . . . . . . . . . . . . . 112
Boots . . . . . . . . . . . . . . . . . . . . . . . . . 17
Brake Fluid . . . . . . . . . . . . . . . . . 84-86
Brake Inspections . . . . . . . . . . . . . . . 87
Brake, Foot . . . . . . . . . . . . . . . . . . . . 38
Brake, Hand . . . . . . . . . . . . . . . . . . . 38
Brake, Parking . . . . . . . . . . . . . . . . . 39
Brakes . . . . . . . . . . . . . . . . . . . . . . . . 87
Break-In Period. . . . . . . . . . . . . . . . . 54
Breather Filter . . . . . . . . . . . . . . . . . . 95
Breather Hose . . . . . . . . . . . . . . . . . . 95
C
Cargo. . . . . . . . . . . . . . . . . . . . . . 32-33
Chrome Wheel Care . . . . . . . . . . . . 117
Cleaning and Storage . . . . . . . 115-120
Clock, Setting Time . . . . . . . . . . . . . 48
Clothing . . . . . . . . . . . . . . . . . . . . . . 17
Clutching (500 EFI) . . . . . . . . . . . . 123
Clutching (800 EFI) . . . . . . . . . . . . 125
Cold Weather Operation . . . . . . . . . . 57
Coolant Bottle. . . . . . . . . . . . . . . . . . 82
Coolant, Radiator . . . . . . . . . . . . . . . 83
Cooling System. . . . . . . . . . . . . . 82-83
Corrosion Removal, Chrome . . . . . 117
D
Demand Drive Fluid . . . . . . . . . . 78-79
Drive Belt Wear/Burn . . . . . . . . . . . 127
Drivetrain Break-In. . . . . . . . . . . . . . 54
Driving Downhill . . . . . . . . . . . . . . . 25
D
Driving in Reverse . . . . . . . . . . . . . . 31
Driving on a Sidehill. . . . . . . . . . . . . 24
Driving on Slippery Surfaces . . . . . . 20
Driving Over Obstacles . . . . . . . . . . 21
Driving Procedures . . . . . . . . . . . . . . 18
Driving Safely. . . . . . . . . . . . . . . 18-33
Driving Through Water . . . . . . . 28-29
Driving Uphill. . . . . . . . . . . . . . . 22-23
E
Electromagnetic Interference . . . . . . 58
Electronic Throttle Control. . . . . . . . 37
Engine Break-In . . . . . . . . . . . . . . . . 54
Engine Fogging. . . . . . . . . . . . . . . . 119
Engine Oil . . . . . . . . . . . . . . . . . . 65-73
Equipment Modifications . . . . . . . . . . 6
Exhaust Emission Control System . . 58
Eye Protection. . . . . . . . . . . . . . . . . . 17
F
Fluid
Brake. . . . . . . . . . . . . . . . . . 84-86
Demand Drive. . . . . . . . . . . 78-79
Rear Gearcase (800 EFI) . . 80-81
Fluid Change
Demand Drive. . . . . . . . . . . . . . 79
Rear Gearcase . . . . . . . . . . . . . . 81
Fluid Level
Rear Gearcase . . . . . . . . . . . . . . 80
Demand Drive. . . . . . . . . . . . . . 78
Fluid Recommendations
Rear Gearcase . . . . . . . . . . . . . . 80
Demand Drive. . . . . . . . . . . . . . 78
Foot Brake . . . . . . . . . . . . . . . . . . . . 38
Footwell Removal. . . . . . . . . . . . . . . 90
Front Gearcase . . . . . . . . . . . . . . 78-79
Fuel Filter . . . . . . . . . . . . . . . . . . . . . 41
Fuel Safety . . . . . . . . . . . . . . . . . . . . 53
Fuel Tank Cap. . . . . . . . . . . . . . . . . . 41
Fuel Valve. . . . . . . . . . . . . . . . . . . . . 41
Fuse Replacement . . . . . . . . . . . . . . . 99
G
Gear Selector . . . . . . . . . . . . . . . . . . 42
Gloves . . . . . . . . . . . . . . . . . . . . . . . . 17
138
INDEX
H
Handlebar Adjustment. . . . . . . . . . . 89
Hauling Cargo . . . . . . . . . . . . . . . 32-33
Hazard Warning Switch. . . . . . . . . . 36
Headlight Beam Adjustment . . . . . . 96
Headlight Lamp . . . . . . . . . . . . . . . . 97
Helmet . . . . . . . . . . . . . . . . . . . . . . . 16
High Range Use. . . . . . . . . . . . . . . . 57
Horn Switch . . . . . . . . . . . . . . . . . . . 36
I
Immersion . . . . . . . . . . . . . . . . 102-103
Instrument Cluster . . . . . . . . . . . . 45-52
K
Key Switch. . . . . . . . . . . . . . . . . . . . 35
K-Turn . . . . . . . . . . . . . . . . . . . . . 26-27
L
Light Switch. . . . . . . . . . . . . . . . . . . 35
Lights
Front Turn Signal. . . . . . . . . . . 98
Headlight Beam Adjustment . . 96
Headlight Lamp . . . . . . . . . . . . 97
Position Light Lamp . . . . . . . . 97
Rear Turn Signal . . . . . . . . . . . 98
Taillight . . . . . . . . . . . . . . . . . . 98
Low Range Use . . . . . . . . . . . . . . . . 57
Lubrication Guide . . . . . . . . . . . . . . 64
M
Maintenance Chart. . . . . . . . . . . . 59-63
Mirrors . . . . . . . . . . . . . . . . . . . . . . . 37
Mode Switch . . . . . . . . . . . . . . . . . . 34
Modifications. . . . . . . . . . . . . . . . . . . 6
N
Noise Emission Control System . . . 58
O
Oil
Engine . . . . . . . . . . . . . . . . . 65-73
Transmission . . . . . . . . . . . . 74-77
Oil Change
Engine (500 EFI) . . . . . . . . . 67-70
Engine (800 EFI) . . . . . . . . . 72-73
Transmission (500 EFI) . . . . . . 75
Transmission (800 EFI) . . . . . . . 77
O
Oil Level
Engine (500 EFI) . . . . . . . . . . . . 66
Engine (800 EFI) . . . . . . . . . . . . 71
Transmission (500 EFI). . . . . . . 74
Transmission (800 EFI). . . . . . . 76
Oil Pump Priming . . . . . . . . . . . . . . . 70
Oil Recommendations
Engine . . . . . . . . . . . . . . . . . . . . 65
Transmission . . . . . . . . . . . . . . . 74
Operator Safety . . . . . . . . . . . . . . . 5-13
Override Switch. . . . . . . . . . . . . . . . . 34
P
Parking Brake . . . . . . . . . . . . . . . . . . 39
Parking on an Incline . . . . . . . . . . . . . 30
Periodic Maintenance Chart . . . . 59-63
Polaris Product List . . . . . . . . . . . . . 126
Polishing the Vehicle. . . . . . . . . . . . 116
Position Light Lamp . . . . . . . . . . . . . 97
Pre-Ride Checklist. . . . . . . . . . . . . . . 55
PVT Break-In . . . . . . . . . . . . . . . . . . 54
PVT Drying . . . . . . . . . . . . . . . . . . . . 58
PVT System. . . . . . . . . . . . 57, 106-107
R
Rear Gearcase Fluid (800 EFI) . . 80-81
Recoil Housing . . . . . . . . . . . . . . . . 108
Recoil Starter . . . . . . . . . . . . . . . . . . . 43
Reverse Operation . . . . . . . . . . . . . . . 31
Reverse Override Switch . . . . . . . . . . 34
Rider Information Center. . . . . . . 46-52
Riding Gear . . . . . . . . . . . . . . . . . 16, 17
S
Safety Decals
"No Passenger" Warning . . . . . . 15
Age 16 Alert . . . . . . . . . . . . . . . 14
General Alert . . . . . . . . . . . . . . . 14
Hill Operation Alert. . . . . . . . . . 14
Rack Warning, Front and Rear . 15
Reverse Override Alert . . . . . . . 15
Tire Pressure/Load Alert . . . . . . 15
Safety Training . . . . . . . . . . . . . . . . . . 6
Service Interval Programming. . . . . . 50
Severe Use . . . . . . . . . . . . . . . . . . . . . 59
Side Panel Removal. . . . . . . . . . . . . . 90
139
INDEX
S
Sidehilling . . . . . . . . . . . . . . . . . . . . 24
Signal Words . . . . . . . . . . . . . . . . . . . 5
Spark Arrestor . . . . . . . . . . . . . 104-105
Spark Arrestor Requirements . . . . . 58
Spark Plugs . . . . . . . . . . . . . . . 100-101
Specifications (500 EFI) . . . . . 122-123
Specifications (800 EFI) . . . . . 124-125
Spring
Adjustment, Rear . . . . . . . . . 89
Starting the Engine . . . . . . . . . . . 56-57
Steering Assembly . . . . . . . . . . . . . . 89
Steering Lock. . . . . . . . . . . . . . . . . . 40
Stop Switch . . . . . . . . . . . . . . . . . . . 35
Storage . . . . . . . . . . . . . . . . . . . 115-120
Sw
itches
AWD
Switch . . . . . . . . . . . . . . 36
Engine Stop Switch . . . . . . . . . 35
Hazard Warning Switch. . . . . . 36
Horn Switch. . . . . . . . . . . . . . . 36
Light Switch . . . . . . . . . . . . . . 35
Main Key Switch . . . . . . . . . . . 35
Mode/Reverse Override Switch 34
Turn Signal Switch . . . . . . . . . 36
T
Taillight . . . . . . . . . . . . . . . . . . . . . . . 98
Throttle Cable Freeplay. . . . . . . . . . . 91
Thro
ttle Lever . . . . . . . . . . . . . . . . . . 37
Tire Tread Depth . . . . . . . . . . . . . . . . 92
Tires
Front
Wheel Hub Tightening. . . 92
Tread Depth . . . . . . . . . . . . . . . . 92
Wheel Installation . . . . . . . . . . . 93
Wheel Nut Torque . . . . . . . . . . . 92
Wheel Removal . . . . . . . . . . . . . 93
Toe Alignment. . . . . . . . . . . . . . . . . . 88
Towing a Disabled Vehicle . . . . . . . 121
Tow
ing Loads . . . . . . . . . . . . . . . . . . 33
Training, Safety . . . . . . . . . . . . . . . . . . 6
Tr
ansmission Oil . . . . . . . . . . . . . 74-77
Transporting the Vehicle . . . . . . . . . 121
Turn
Signal Lamp, Front . . . . . . . . . . 98
Turn Signal Lamp, Rear . . . . . . . . . . 98
Turn
Signal Switch . . . . . . . . . . . . . . 36
Turning
Around on a Hill . . . . . . 26-27
Turning the Vehicle. . . . . . . . . . . . . . 19
V
Vehicle Identification Numbers. . . . . . 4
Ve
hicle Immersion . . . . . . . . . 102-103
W
Warning Symbols . . . . . . . . . . . . . . . . 5
Wa
shing the Vehicle . . . . . . . . 115-116
Wh
eel Hub Tightening . . . . . . . . . . . 92
Wh
eel Installation . . . . . . . . . . . . . . . 93
Wheel Nut Torque Specifications . . . 92
Wh
eel Removal . . . . . . . . . . . . . . . . . 93
