1
WELCOME
Thank you for purchasing a P olaris vehicle, and welcome to our
world-wide family of Polaris owners. We proudly produce an exciting
line of utility and recreational products:
S Snowmobiles
S All-terrain vehicles (ATVs)
S RANGER utility vehicles
S Victory motorcycles
Always follow the instructions and recommendations in this manual.
The manual contains instructions for minor maintenance, but
information about major repairs is outlined in the Polaris Service
Manual and should be performed only by a Factory Certified Master
Service Dealer (MSD) Technician. P lease 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
Copyright 2005 Polaris Sales Inc. All information contained with in this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor
discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference
use only. Manufacturer accepts no liability 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 Taiwan
2006 Phoenix 200 Quadricycle Owner ’s Manual P/N 9920249
3
TABLE OF CONTENTS
VEHICLE IDENTIFICATION NUMBERS 5........
SAFETY 6...................................
FEATURES A ND CONTROLS 38...............
OPERATION 48..............................
EMISSION CONTROL SYSTEMS 52............
MAINTENANCE AND LUBRICATION 53.........
POLARIS P RODUCTS 93......................
SPECIFICATIONS 94.........................
TROUBLESHOOTING 96......................
WA RRANTY 99...............................
MAINTENANCE RECORD 101.................
INDEX 103...................................
4
5
VEHICLE IDENTIFICATION NUMBERS
Record your vehicle’s identification numbers in the spaces provided.
Remove the spare key and store it in a safe place. If both keys are lost,
the ignition switch must be replaced.
Vehicle Model Number:
Frame VIN (1):
Engine Serial Number (2):
1
2
6
SAFETY
Operator Safety
The following signal words and symbols appear throughout this
manual and on your vehicle. Become familiar with their meanings
before reading the manual.
The safety alert symbol, on your vehicle or in this manual, alerts
you to the potential for personal injury.
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 personal injury or damage to the vehicle.
CAUTION
A caution indicates a situation that may result in damage to the
vehicle.
NOTE:
A note will alert you to important information or instructions.
7
SAFETY
Operator Safety
WARNING
Failure to follow the warnings in this manual can result in serious
injury or death.
A Polaris Quadricycle is not a toy and can be hazardous to
operate. A collision or rollover can occur quickly, even during
routine maneuvers, if you fail to take proper precautions.
Read and understand your owner’s manual and all warnings
before operating a Polaris Quadricycle.
Safety Training
When you purchased your new Quadricycle, your dealer offered a
hands-on safety training course. You were also provided with printed
materials that explain safe operating procedures. Review this
information 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 Restriction
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age.
8
SAFETY
Operator Safety
Know Your Vehicle and Riding Area
You are responsible for your personal safety, the s afety of others and
the protection of the environment. Read and understand your owner’s
manual. It includes important information about Quadricycle safety.
Ride responsibly. Know all laws and regulations concerning the
operation of this vehicle in your area.
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) mowers, blades, tires, sprayers and large racks may
change vehicle handling. Use only Polaris-approved
accessories. Know their function and effect on the vehicle.
<
9
SAFETY
Operator Safety
WARNING
Serious injury or death can result if you do not follow the
instructions and procedures listed here and throughout this
manual.
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.
50
40
0
10
20
30
10
SAFETY
Operator Safety
Never carry a passenger on
the rear rack. Ejection from
the vehicle or contact with
moving components can result
in serious injury or death.
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.
11
SAFETY
Operator Safety
Never attempt wheelies, jumps or
other stunts.
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 49.
Keep both hands on
the handlebars. Keep
your feet on the
footrests.
Always travel slowly when
operating on unfamiliar
terrain. Use extra caution.
12
SAFETY
Operator Safety
Use caution when operating
on rough, slippery or loose
terrain.
Always follow the procedures
outlined in this manual for
turning. See page 26.
Never turn sharply at
excessive speeds, which can
lead to vehicle overturn.
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.
>25_
13
SAFETY
Operator Safety
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 30.
Always follow the procedures
outlined in this manual for driving
downhill and for braking on
hills. See page 29.
Always follow the procedures
outlined in this manual for crossing
the side of a hill. See page 34.
Never attempt to turn the Quadricycle
around on any hill until you’ve
mastered (on level ground) the
turning technique outlined in this
manual.
14
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 31.
Always follow the procedures
outlined in this manual for
operating over obstacles.
See page 28.
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 27.
15
SAFETY
Operator Safety
Always follow the
procedures outlined in
this manual for driving
through water. Never
drive through deep or
fast-flowing water . See
page 36.
Always follow the procedures
outlined in this manual for
driving in reverse. See page 35.
Always use t he size
and type of tires specified
for your Quadricycle.
Maintain the proper
tire pressure.
31.7 kg
16
SAFETY
Operator Safety
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.
Never operate the Quadricycle on
a frozen body of water .
Operating on paved surfaces may
seriously affect the handling and
control of the Quadricycle and
could result in loss of control,
accident and/or injury.
Avoid sudden turns or swift
movement of the
handlebars.
17
SAFETY
Operator Safety
Always remove the ignition
key when the vehicle is not
in use to prevent
unauthorized use or
accidental starting.
Always keep combustible materials away from the exhaust
system. Exposure of combustibles to hot components could
result in a fire.
FOR MORE INFORMATION ABOUT QUADRICYCLE SAFETY,
call Polaris at 1-800 -342-3764.
A
B
C
D
F
G
H
E
18
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.
Decal Text
Never operate this vehicle on
hills steeper than 25 degrees.
To prevent flipover on hilly
terrain, when going up or
down, use throttle and brakes
gradually.
A
19
SAFETY
Safety Decals and Locations
NO STEP
B
C
D
E
7172566
WARNING
F
20
SAFETY
Safety Decals and Locations
Decal Text
NEVER ride as a passenger.
Passengers can cause
a loss of control, resulting
in SEVERE INJURY or DEATH.
TIRE PRESSURE IN PSI (KPa):
FRONT 4 (27.6) REAR 4 (27.6)
MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight)
INCLUDING MACHINE, DRIVER AND CARGO IS 720 LBS. (326 kg)
MAXIMUM CARGO CAPACITY 70 LBS. (31.7 kg)
Read Owner ’s Manual for more detailed loading information.
7173303
21
SAFETY
Safety Decals and Locations
Decal Text (G)
DO NO T TOW F ROM RA CK O R B UMPER. Vehic le damage or t ip-
over may result causing sev ere injur y or death. Tow only from tow
hooks or hit ch. Max. Rack Load 70 lbs. (31.7 kg).
Decal Text (H)
S Operation of this vehicle without the air filter element will severely
damage the engine.
S Clean pre-filter element often, more frequent cleaning required in
dusty conditions. Do not operate vehicle without pre-filter.
S Specific carburetor jetting and adjustments are required depending
on temperature and altitude. See your Owner’s Manual.
Factory setting:
40_ to 80_ F. at 0-3000 feet (5_ to 27_ C. at 0-900 meters).
Hitch Decal
Exceeding vehicle towing limit could lead to an
accident. Reduce speed when towing a trailer.
Read owner’s manual for details. Trailer Tongue
Weight should be about 10% of the Gross Trailer
Weight, and should not exceed 13.6 kg (30 lbs).
MAXIMUM TOWING CAPACITY: 136 KG (300 lbs)
7173373
G
DO NOT TOW FROM RACK OR BUMPER. Vehicl e damage or tipov er may result causing sev ere injury or
death. Tow only from tow hooks or hi tch. Max. Rack 70 lbs. (31.7 kg)
H
S Operation of this vehicle
without the air filter
element will severely damage the
engine.
S Clean pre-filter element often,
more frequent cleaning
required in dusty conditions.
Do not operate vehicle without
pre-filter.
ATTENTION
S Specific
carburetor jetting
7170007
and adjustments are required
depending on temperature
and altitude. See your Owner’s
Manual.
Factory setting:
40_ to 80_ F. at 0-3000 feet
(5_ to 27_ C. at 0-900 meters).
1
2
3
4
5
22
SAFETY
Safe Riding Gear
Always wear protective clothing to reduce the chance of injury.
1. Helmet
Always wear a helmet that meets or
exceeds established safety standards. A
helmet can prevent a severe head injury.
2. Eye Protection
Wear shatterproof goggles or a
shatterproof helmet face shield. Use a
lens anti-fogging product to keep them
clean.
3. Gloves
Wear off-road style gloves with knuckle
pads.
4. Boots
Wear strong over-the-calf boots with
heels, like moto-cross boots.
5. Clothing
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. Do not wear loose clothing
that can get entangled in the vehicle, tree
branches or shrubs.
23
SAFETY
Driving Safely
Driving Procedu res
1. Sit upright. Keep your feet on the footrests. Keep both hands on the
handlebars.
2. Squeeze the brake lever.
3. Start the engine and allow it to warm up, then shift the transmission
into gear.
4. Check your surroundings and determine your path of travel.
5. Release the brake lever.
6. Slowly squeeze the throttle lever toward the handlebar to begin
driving. Squeeze the throttle lever further to increase speed.
7. Drive slowly. Practice maneuvering and using the throttle and brakes
on level surfaces.
24
SAFETY
Driving Safely
Hauling Cargo and Towing
WARNING
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.
S REDUCE SPEED AND ALLOW GREATER DISTANCES FOR
BRAKING WHEN HAULING CARGO OR TOWING.
S When operating over rough or hilly terrain, reduce speed, cargo
and towed load to maintain stable driving conditions.
S CARRY LOADS AS LOW ON THE RACK AS POSSIBLE. Car-
rying a load high on the rack raises the center of gravity of the
vehicle and creates a less stable operating condition.
S SECURE ALL LOADS BEFORE OPERATING. Unsecured
loads can create unstable operating conditions, which could
result in loss of control of the vehicle.
S 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.
S HEAVY LOADS CAN CAUSE BRAKING AND CONTROL
PROBLEMS. Use extreme caution when applying brakes with a
loaded vehicle and when towing. Avoid terrain or situations that
may require backing downhill.
S 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.
S DO NOT CARRY LOADS ON THE FRONT OF THE VEHICLE.
S DO NOT TRAVEL FASTER THAN THE RECOMMENDED
SPEEDS. The vehicle should never exceed 10 mph (16 kph)
while towing a load on a level grass surface. Vehicle speed
should never exceed 5 mph (8 kph) when towing loads in rough
terrain, while cornering, or while ascending or descending a hill.
25
SAFETY
Driving Safely
Hauling Cargo and Towing
Load Distribution
Read and understand the load distribution warnings listed on the
vehicle warning labels. Never exceed the specified weights. Your
Quadricycle may carry a maximum of 31.7 kg of cargo on the rear
rack. It m ay tow a maximum of 136 kg with a maximum tongue
weight of 13.6 kg.
Load cargo as low as possible. When operating over rough or hilly
terrain, reduce cargo and drive slowly to maintain stable driving
conditions.
1. Operate with extreme caution when hauling car go or towing loads.
Balance, handling and control may be affected.
2. Slow down.
Towing
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°.
PHOENIX 200
QUADRICYCLE
Maximum Towed Load
(Level Ground)
Maximum Vertical Hitch
Weight
136 kg 13.6 kg
31.7 kg
50
40
0
10
20
30
26
SAFETY
Driving Safely
Making Turns
1. To make a t urn, 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.
2. Practice turning at slow speeds
before attempting to t urn 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.
27
SAFETY
Driving Safely
Driving o n 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. Use extra caution.
3. Be alert. Watch the trail. 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.
28
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.
50
40
0
10
20
30
29
SAFETY
Driving Safely
Driving Downh ill
Whenever descending a hill,
follow these precautions:
1. Check the terrain carefully.
2. Avoid hills with excessively
slippery or loose surfaces.
3. Never go down a hill at high
speed.
4. Slow down.
5. Avoid going down a hill at
an angle, which can cause
the vehicle to pitch sharply
to one side.
6. Drive straight downhill.
7. Shift your weight rearward.
8. Apply the brakes slightly toaidinslowing.
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.
<25_
30
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_
31
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 rear brakes while rolling backwards.
Apply the foot brake gradually. When fully stopped, squeeze the brake
lever as well.
Dismount on the uphill side, or to either side if the vehicle is pointed
straight uphill. Turn the vehicle around and remount, following the
procedure described on page 32.
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.
2.4 m
32
SAFETY
Driving Safely
Turning Around on a Hill
If the vehicle stalls while climbing a hill, NEVER BACK DOWN THE
HILL! Use the K-turn to turn around.
1. Apply the all-wheel foot brake to stop the vehicle.
2. Keep your weight uphill.
3. Squeeze and hold the brake lever while completing steps 4-6.
4. Leave the transmission in forward gear. Turn the engine off.
5. Dismount on the uphill side of the vehicle, or on the left if the
vehicle is pointing straight uphill.
6. Stay uphill of the vehicle and turn the handlebars full left.
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.
>25_
33
SAFETY
Driving Safely
Turning Around on a Hill
8. Squeeze the brake lever. Remount from the uphill side. Keep your
weight uphill.
9. With the transmission still in forward, start t he engine.
10. Release the brake lever and drive slowly downhill. Control speed
with the brake lever until the vehicle is on level ground.
Always follow the procedures
outlined in this manual for
climbing hills. See page 30.
Always follow the procedures
outlined in this manual for crossing
the side of a hill. See page 34.
34
SAFETY
Driving Safely
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.
Neverattempttoturnthe
Quadricycle around on any hill until
you’ve mastered (on level ground)
the turning technique outlined in this
manual.
35
SAFETY
Driving Safely
Driving in Reverse
Follow these precautions when operating in reverse:
1. Avoid backing downhill.
2. Always check for obstacles or
people behind t he vehicle
before backing.
3. Drive slowly.
4. Apply the brakes
lightly for stopping.
5. Avoid turning at
sharp angles.
6. Never apply the throttle
suddenly.
Always follow the procedures
outlined in this manual for
driving in reverse.
1
36
SAFETY
Driving Safely
Driving Through Water
Follow these procedures when operating through water:
1. Check water depth and current before crossing.
2. Avoid operating in
water deeper than the
bottom of the footrests (1).
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, s tops or
throttle changes.
3. Choose a crossing where
both banks have gradual inclines.
4. Drive slowly.
5. Avoid rocks and obstacles.
6. 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.
Always follow the
procedures outlined in
this manual for driving
through water. Never
drive through deep or
fast-flowing water .
37
SAFETY
Driving Safely
Driving Through Water
CAUTION
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.
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 80.
Have the vehicle serviced by your dealer promptly.
NOTE: If water has been ingested into the transmission (CVT),
follow the procedure for drying out the CVT. See page 83.
ParkingonanIncline
Avoid parking on an incline. If it’s unavoidable, follow these
precautions:
1. Turn the engine off.
2. Place the transmission in gear.
3. Lock the parking brake.
4. Always block the rear wheels on the downhill side.
5. Turn the fuel valve off.
(1)
(3)
(4)
(2)
38
FEATURES AND CONTROLS
Controls/Instruments
(1)Main Key Switch
Turn off the main switch t o stop the engine and end all electrical
power to the vehicle.
ThemainkeyswitchmustbeintheON position before starting
the engine. The headlights are not on in this position.
Move the key switch t o the LIGHTS ON position to turn t he
headlight on.
WARNING
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.
(2)Start Switch
Press the start switch toward the
handlebar to engage the starter.
NOTE: The starter will not
engage unless the rear
brakes are applied. See
page 50 for engine
starting procedures.
(2)
(3)
(4)
39
FEATURES AND CONTROLS
Controls/Instruments
(3)Light Switch/Hi-Lo Beam Control
Toggle t he headlight from high beam to low
beam.
NOTE: Move the main key switch to the
LIGHTS ON position to turn the
headlight on.
(4)Throttle lever
Press the throttle lever to increase
engine speed and vehicle
movement. Release the lever to
reduce engine speed and vehicle
movement.
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.
(6)
(5)
(7)
(8)
40
FEATURES AND CONTROLS
Controls/Instruments
(5)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.
WARNING
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.
(6)Choke Lever
The choke assists i n starting a
cold engine. See page 50.
(7)Horn Switch
Press the horn button to
alert others of your
presence.
(8)Hazard Warning Switch
Push the hazard warning switch
to cause all turn indicators to
flash simultaneously. Use this
feature t o alert others of an
emergency or other situation
requiring caution.
(7)
(6)
(8)
(9)
(10)
(11)
41
FEATURES AND CONTROLS
Controls/Instruments
(9)Rear Brake Lever
The brake lever operates the rear
brakes only. Squeeze the brake lever
toward the handlebar to apply the rear
brakes.
NOTE: Since the brake lever operates
the rear brakes only, it is not as
effective as the all-wheel foot brake.
If the rear wheels begin to skid or slide while using this
brake, reduce lever pressure.
WARNING
Aggressively applying the rear brake when backing down a hill
may cause rear tipover.
Aggressively applying the rear brake while moving forward may
cause the rear wheels to skid and result in loss of control.
(10)Turn Indicator Switch
Push the toggle switch either left or
right to activate the corresponding
turn signal. Return the toggle to the
center position to end the signal.
(11)Mirrors
Use the mirrors to assist in traffic
maneuvers. Always check and adjust t he
mirrors before driving the Quadricycle.
42
FEATURES AND CONTROLS
Controls/Instruments
Indicator Lights
View vehicle functions on the
instrument panel. Each light
illuminates when the feature i s
activated.
N
Neutral Indicator
High Beam Indicator
Hazard Warning Indicator
Turn Signal Indicator
R
Reverse Gear Indicator
1
2
43
FEATURES AND CONTROLS
Foot Brake
The all-wheel foot brake is
located on the right footrest.
Press the brake pedal forward
with your foot to engage all four
brakes, providing maximum
stopping power.
Inspect and maintain the brake
fluid level as outlined in this
manual. See page 68.
Parking Brake
WARNING
Operating the vehicle while the parking brake is engaged could
result in an accident and serious injury or death. Always check to
be sure the parking brake is disengaged before operating.
Locking th e Parking Brake
1. Squeeze the brake lever (1).
2. Push the park brake lock (2)
down. This will prevent
the lever from
returning to the
released position.
3. To release t he parking
brake lock, squeeze and
release the brake lever. The
parking brake will release automatically.
Important Safeguards
S The parking brake may relax if left locked for a long period of time.
Always block the wheels t o prevent rolling.
S Never depend on the parking brake alone if the vehicle is parked on
a hill. Always block the wheels to prevent rolling.
44
FEATURES AND CONTROLS
Fuel Safety
WARNING
S Gasoline is highly flammable and explosive under certain
conditions.
S Use extreme caution whenever handling gasoline.
S Refuel with the engine stopped. Refuel outdoors or in a well
ventilated area.
S Do not smoke or allow open flames or sparks in or near the
area where refueling is performed or where gasoline is stored.
S Do not overfill the tank. Do not fill the tank neck.
S If gasoline spills on your skin or clothing, immediately wash it off
with soap and water and change clothing.
S Turn the fuel valve off whenever the vehicle is stored or parked.
1
2
45
FEATURES AND CONTROLS
Fuel Tank
The fuel tank filler cap (1) is located directly below the handlebar. The
gauge in the cap shows the approximate amount of fuel remaining.
Refuel with either leaded or unleaded gasoline with a minimum of 87
octane.
Fuel Valve
The fuel valve (2) is located
on the left side of the vehicle.
OFF
Turn the valve off
before storage and
when transporting.
ON
Turn the valve on for
normal operation.
RES
Turn the valve to the
reserve setting if the
main fuel supply i s
exhausted. Refuel as
soon as possible.
Reserve fuel range is
about 11-16 km.
NOTE: Return the valve to the ON position after refueling.
1
FNR
46
FEATURES AND CONTROLS
Transmission Gear Selector
The transmission gear selector (1)
is located on the right side of the
vehicle. Whenever the vehicle is
left unattended, place the
transmission in gear and lock the
parking brake.
F: Forward Gear
N: Neutral
R: Reverse Gear
CAUTION
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 lever to the desired
gear.
47
FEATURES AND CONTROLS
Kick-Start Lever
If the battery becomes t oo weak to start the engine, use the kick-start
lever to start the engine until the battery is serviced.
1. Position the vehicle on a level
surface.
2. Lock the parking brake.
3. Place the transmission in
neutral.
4. Fold out the kick-start lever on
the left side of the vehicle.
5. Make sure the main key switch
is on.
6. Place your foot on the kick-start
lever. Thrust your heel downward to
crank the engine.
NOTE: If the engine is cold, use the
choke as outlined on page 50.
7. After the engine starts, fold the kick-start lever back into place.
NOTE: A 10/12 mm wrench is provided in the tool kit for removing or
installing the lever . If not installed, make sure the rubber cap
is installed on the kick-start shaft to protect the rider. The
storage area for the kick-start lever is on the left side of the
frame above the rear swing arm pivot.
FNR
48
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 t anks of
gasoline. No single action on your part will increase the life and
performance of your Quadricycle more t han following the procedures
for a proper break-in. Careful treatment of a new engine will result in
more efficient performance and a longer life.
Do not operate at full throttle or high speeds for extended periods
during the first three hours of use.
Perform the following procedures carefully.
1. Fill the fuel tank with gasoline.
2. Check the oil level. Add oil if necessary. See page 59.
3. Select an open area that allows room to familiarize yourself with
vehicle operation and handling.
4. Drive slowly. Vary 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 49.
6. Pull only light loads.
7. Perform the break-in oil change at one month.
49
OPERATION
Pre-Ride Inspection
Pre-Ride Checklist
Item Remarks See
Page
Brake system / lever travel Ensure proper operation 67, 69
Brake fluid Ensure proper level 68
Foot brake Ensure proper operation 43
Front suspension Inspect, lubricate if necessary --
Rear suspension Inspect, lubricate if necessary --
Steering Ensure free operation --
Tires Inspect condition and pressure 76
Wheels / fasteners Inspect, ensure fastener tightness 74
Frame nuts, bolts, fasteners Inspect, ensure tightness --
Fuel and oil Ensure proper levels 45, 59
Throttle Ensure proper operation 39, 73
Indicator lights / switches Ensure operation 40, 42
Air filter, pre-filter Inspect, clean 77
Air box sediment tube Drain deposits whenever visible --
Headlamp Check operation, apply Polaris dielec-
tric grease when lamp is replaced
88
Brake light / tail lamp Check operation, apply Polaris dielec-
tric grease when lamp is replaced
88
Riding gear Wear helmet, goggles, protective
clothing
22
50
OPERATION
Starting the Engine
WARNING
Engine exhaust contains poisonous carbon monoxide and can
cause loss of consciousness resulting in serious injury or death.
Never run an engine in an enclosed area or indoors.
CAUTION
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. Sit on the vehicle.
3. Squeeze the brake lever.
4. Turn the fuel valve on.
5. Turn the main key switch on.
6. If the engine is cold, use full choke
by pushing the choke lever all the
way to the left. A warm engine will
not require the use of the choke.
NOTE: The choke is fully on when the
lever is pushed completely to the
left. The choke is off when the
lever is pushed completely to the
right. The choke can be adjusted
gradually, depending on how much
choke is needed for starting.
51
OPERATION
Starting the Engine
7. Press the start switch.
NOTE: Do not press the throttle
while starting the engine.
8. Activate the starter for a m aximum
of five seconds. Release t he start
switch when t he engine starts. If it
doesn’t start, release the switch,
wait five seconds, then activate for
another five seconds. R epeat until
the engine starts.
9. If the engine slows or stops, position
the choke lever half way to allow
proper engine warm up. Vary the RPM
slightly with the throttle to aid in warm
up.
10. When the engine idles smoothly, push
the choke lever all the way to the right.
11. Allow the engine to warm up for
several minutes before driving.
Cold Weather Operation for 4-Cycle Engines
Internal engine condensation increases as outside temperatures
decrease. If the vehicle is used year-round, check the oil level
frequently. A rising oil level could indicate condensation in the bottom
of the crankcase, which can lead to engine damage. Any condensation
must be drained. If the oil level rises to the top of the sight glass,
change the oil immediately.
Always operate the engine long enough to reach operating temperature,
which reduces condensation.
52
EMISSION CONTROL SYSTEMS
Noise Emission Control System
Do not modify the engine, intake or exhaust components, as doing so
may affect compliance with state and local noise level requirements.
Crankcase Emission Control System
This engine is equipped with a closed crankcase system. B l ow-by
gases are forced back to the combustion chamber by the intake system.
The system does not allow t he blow-by gases to enter the atmosphere.
Exhaust Emission Control System
The emissions from the exhaust of this vehicle are controlled by engine
design, including factory-set fuel delivery and ignition. The engine
and related components must be m aintained at Polaris specifications to
achieve optimal performance.
Adjustment to engine idle is the only adjustment Polaris recommends
that the operator perform. Any other adjustments should be performed
by an authorized Polaris dealer.
WARNING
The installation of devices that effectively increase exhaust
emissions beyond their legal limits will void all manufacturer
warranties and may violate laws governing the registration and
operation of this vehicle.
Electromagnetic Interference
This spark i gnition system complies with Canadian ICES--002 and
European directives 97/24/EC and 89/336/EEC.
53
MAINTENANCE AND LUBRICATION
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.
Severe Use Definition
S Frequent immersion in mud, water or sand
S Racing or race-style high RPM use
S Prolonged low speed, heavy load operation
S Extended idle
S Short trip cold weather operation
NOTE: Service and adjustments are critical. If you are not familiar
with safe service and adjustment procedures, have a
qualified Polaris dealer perform these operations.
Maintenance Chart Key
" Perform these procedures more frequently for vehicles subjected to
severe use.
E Emission Control System Service
J Have an authorized Polaris dealer perform these services.
WARNING
Improperly performing the procedures marked with a J could
result in component failure and lead to serious injury or death.
Have an authorized Polaris dealer perform these services.
54
MAINTENANCE AND LUBRICATION
Periodic Maintenance Chart
Perform all services at whichever maintenance interval is reached first.
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Kilometers
J
Steering -- Pre-Ride --
Make adjustments as need-
e
d
S
e
e
P
r
e
R
i
d
e
C
h
e
c
k
l
i
s
t
"
Front suspension -- Pre-Ride --
j
ed. See Pre-Ride Checklist
on pa
g
e 49.
"
Rear suspension -- Pre-Ride --
o
n
p
a
g
e
4
9
.
Tires -- Pre-Ride --
"
Brake fluid level -- Pre-Ride --
"
Brake lever travel -- Pre-Ride --
Brake systems -- Pre-Ride --
Wheels/fasteners -- Pre-Ride --
Frame fasteners -- Pre-Ride --
"
E
Engine oil level -- Pre-Ride --
"
E
Air filter, pre-filter -- Daily -- Inspect; clean often
"
E
Air box sediment
tube
-- Daily -- Drain deposits when visible
Coolant
(if applicable)
-- Daily -- Check level daily , change
coolant every 2 years
Headlamp/tail
lamp
-- Daily -- Check operation; apply
dielectric grease if replacing
"
E
Air filter,
main element
-- Weekly -- Inspect; replace as needed
Recoil housing
(if equipped)
-- Weekly -- Drain water as needed,
check often if operating in
wet conditions
"
J
Brake pad wear 10 Monthly 100 Inspect periodically
Battery 20 Monthly 200 Check terminals; clean; test
"
Front gearcase oil
(if equipped)
25 Monthly 250 Inspect level; change yearly
"
Middle gearcase
oil (if equipped)
25 Monthly 250 Inspect level; change yearly
"
Rear gearcase oil
(if equipped)
25 Monthly 250 Inspect level; change yearly
"
Transmission oil 25 Monthly 250 Inspect level; change yearly
" Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service
J Have an authorized Polaris dealer perform these services.
55
MAINTENANCE AND LUBRICATION
Periodic Maintenance Chart
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Kilometers
"
E
Engine breather
filter (if equipped)
25 Monthly 250 Inspect; replace if necessary
"
E
Engine oil change
(break-in)
25 1M 250 Perform a break-in oil
change at one month
"
General
lubrication
50 3M 500 Lubricate all fittings, pivots,
cables, etc.
Shift Linkage 50 6M 500 Inspect, lubricate, adjust
J
Steering 50 6M 500 Lubricate
"
Front suspension 50 6M 500 Lubricate
"
Rear suspension 50 6M 500 Lubricate
Carburetor float
bowl
50 6M 500 Drain bowl periodically and
prior to storage
J
E
Throttle Cable/
ETC Switch
50 6M 500 Inspect; adjust; lubricate;
replace if necessary
J
E
Choke cable 50 6M 500 Inspect; adjust; lubricate;
replace if necessary
E
Carburetor air
intake ducts/
flange
50 6M 500 Inspect ducts for proper
sealing/air leaks
Drive belt 50 6M 500 Inspect; adjust; replace as
needed
Cooling system
(if applicable)
50 6M 500 Inspect coolant strength
seasonally; pressure test
system yearly
"
E
Engine oil change 100 6M 1000 Perform a break-in oil
change at one month
"
E
Oil filter change 100 6M 1000 Replace with oil change
J
E
Valve clearance 100 12 M 1000 Inspect; adjust
" Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service
J Have an authorized Polaris dealer perform these services.
56
MAINTENANCE AND LUBRICATION
Periodic Maintenance Chart
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Kilometers
J
E
Fuel system 100 12 M 1000) Check for leaks at tank cap,
lines, fuel valve, filter, pump,
carburetor; replace lines
every two years
J
E
Fuel filter 100 12 M 1000 Replace yearly
"
Radiator
(if applicable)
100 12 M 1000 Inspect; clean external
surfaces
"
Cooling hoses
(if applicable)
100 12 M 1000 Inspect for leaks
"
Engine mounts 100 12 M 1000 Inspect
Exhaust muffler/
pipe
100 12 M 1000 Inspect
J
E
Spark plug 100 12 M 1000 Inspect; replace as needed
J
E
Ignition Timing 100 12 M 1000 Inspect
"
Wiring 100 12 M 1000 Inspect for wear, routing,
security; apply dielectric
grease to connectors
subjected to water, mud, etc.
J
Clutches (drive
and driven)
100 12 M 1000 Inspect; clean; replace worn
parts
J
Front wheel
bearings
100 12 M 1600 Inspect; replace as needed
J
Brake fluid 200 24 M 2000 Change every two years
E
Idle speed -- Adjust as needed
J
Toe adjustment -- Inspect periodically; adjust
when parts are replaced
"
J
Foot brake -- Inspect daily; adjust as
needed
Headlight aim -- Adjust as needed
" Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service
J Have an authorized Polaris dealer perform these services.
57
MAINTENANCE AND LUBRICATION
Torque Symbol
=Torque the item as specified.
Lubrication Recommendations
Check and lubricate all components at the intervals outlined in the
Periodic M aintenance Chart beginning on page 53. Items not listed in
the chart should be lubricated at the General Lubrication interval.
Item Lube Method
Engine Oil PS-4 0W50 See page 58.
Brakes DOT 3 fluid only See page 67.
Transmission Premium AGL Synthetic
Gearcase Lube
See pages 63-64.
Rear Gearcase Premium vehicle Angle
Drive Fluid
See pages 65-66.
(1) Front A-Arms FGrease Inspect; tighten fasteners;
grease (also after washing
vehicle or driving in water)
(1)
58
MAINTENANCE AND LUBRICATION
Engine Oil
Polaris PS-4 Synthetic 0W50 Oil is the only oil recommended for use
in this engine. Use of another API certified “SH” oil is acceptable as
long as it’s 0W-50. Oil may need to be changed more frequently if
Polaris PS -4 is not used. See page 93 for the part numbers of Polaris
products.
Always check and change the engine oil at the intervals outlined in the
Periodic Maintenance Chart beginning on page 53.
CAUTION
Using a non-recommended oil may cause serious engine damage.
Never substitute or mix oil brands.
59
MAINTENANCE AND LUBRICATION
Oil Check
NOTE: A rising oil level between checks in cool weather driving can
indicate contaminants such as gas or moisture collecting in
the crankcase. If the oil level rises to the top of the sight
glass, change the oil immediately.
1. Position the vehicle on a
level surface.
2. Squeeze the brake lever.
3. Start the engine. Allow
it to idle for 30 seconds.
4. Turn the engine off.
5. Lock the parking brake.
6. View the oil level. The
oil level should be at
the center of the sight
glass.
7. Add oil as needed.
60
MAINTENANCE AND LUBRICATION
Oil and Filter Change
Always change the engine oil at the intervals outlined in the Periodic
Maintenance Chart beginning on page 53. Always change the oil filter
when changing oil. Change the oil more often if the vehicle is routinely
subjected to:
S operation in dusty or wet conditions.
S operation when air temperature is below -12° C.
S short trips at -12° to -1° C. (engine fails to reach operating tempera-
ture).
CAUTION
If the Quadricycle is left without oil in the system for extended
periods, the oil pump may lose its prime, which could result in
engine damage. Always replace the oil and filter within a few
hours of draining the oil. Do not allow the vehicle to be without oil
overnight.
1. Use Polaris-recommended
products.
2. Position the vehicle on a
level surface.
3. Squeeze the brake lever.
4. Start the engine. Allow
it to idle for two minutes.
5. Turn the engine off.
6. Lock the parking brake.
61
MAINTENANCE AND LUBRICATION
Oil and Filter Change
7. Place a drain pan under the
vehicle.
8. Remove the drain plug.
9. Drain the oil.
CAUTION
Hot oil may result in serious burns. Do not allow hot oil to contact
skin.
10. Reinstall the drain plug with a new
sealing washer.
=15 N-m
11. Place towels under the oil
filter.
12. Using an oil filter wrench, turn
the filter counterclockwise to
remove it.
13. Clean the filter sealing area on
the engine.
62
MAINTENANCE AND LUBRICATION
Oil and Filter Change
14. Lubricate the filter o-ring.
15. Install the new oil filter.
After the filter contacts the
engine surface, turn it 1/2
turn by hand.
16. Remove the oil fill
plug.
17. Add 850 ml of 0W/50 oil.
18. Reinstall the fill plug.
19. S tart the engine. Allow
it to idle for two
minutes.
20. Turn the engine off.
21. Check for oil leaks.
22. Check the oil level.
23. Add oil as needed.
24. Discard used oil and
filter properly.
63
MAINTENANCE AND LUBRICATION
Gearcase Specification Chart
Gearcase Lubricant Capacity Fill Plug
Torque
Drain/Check
Plug Torque
Transmission Premium AGL Synthetic
Gearcase Lubricant
550 ml N/A 24 Nm
Rear Gearcase Premium ATV Angle
Drive Fluid
120 ml 34 Nm 24 Nm
Transmission Oil Check
1. Position the vehicle on a
level surface.
2. Place the transmission in
gear.
3. Lock the parking brake.
4. View the oil level
through the sight glass.
The oil level should be
between 1/4 and 3/4.
5. Add fluid as needed.
6. Reinstall the fill plug.
FNR
1/4
3/4
64
MAINTENANCE AND LUBRICATION
Transmission Oil Change
1. Position the vehicle on a
level surface.
2. Place the transmission in
gear.
3. Lock the parking brake.
4. Remove the fill plug.
5. Remove the drain plug.
6. Drain the fluid into a
drain pan.
7. Reinstall the drain plug.
=24 N-m
8. Add 550 ml of the
recommended fluid.
9. Reinstall the fill plug.
10. Check for leaks.
FNR
65
MAINTENANCE AND LUBRICATION
Rear Gearcase Oil Check
1. Position the vehicle on a
level surface.
2. Place the transmission in
gear.
3. Lock the parking brake.
4. Remove the check plug.
View the oil level. The
oil level should be at the
bottom of t he plug hole.
5. Remove the fill plug. Add
fluid as needed.
6. Reinstall the fill plug.
=34 N-m
7. Reinstall the check plug.
=24 N-m
FNR
66
MAINTENANCE AND LUBRICATION
Rear Gearcase Oil Change
1. Remove the skid plate.
2. Remove the drain plug.
3. Drain the fluid into a drain pan.
4. Clean and reinstall the drain plug
with a new sealing washer.
=24 N-m
5. Remove the fill plug.
6. Add 120 ml of the recommended
fluid.
7. Reinstall the fill plug.
=34 N-m
8. Check for leaks.
9. Reinstall the skid plate.
1mm
67
MAINTENANCE AND LUBRICATION
Brakes
Under normal operation, a 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. The brake system should be inspected by your dealer.
Fill the reservoir as needed whenever the cover is loosened or removed
to ensure proper diaphragm operation. Use Polaris DOT 3 brake fluid.
Do not overfill.
NOTE: Reservoir levels will decrease as brake pads become worn.
When checking the fluid level, the vehicle must be on level
ground with the handlebars straight. If the fluid level is low,
check brake pad thickness before adding brake fluid. DO
NOT OVERFILL.
Brake Check
Perform the following checks to keep the brake systems in good
operating condition. Check more often if brakes are used heavily
during normal operation.
WARNING
Do not overfill the reservoir. An over-full master cylinder may
cause brake drag or brake lock-up, which could cause brake loss
or loss of control. Maintain brake fluid at the recommended level.
1. Check the brake systems regularly for
fluid leaks.
2. Check the brakes for excessive travel
or spongy feel.
3. Check the brake pads for wear,
damage or looseness. Replace pads
when they are worn to 1 mm.
4. Check the security and surface
condition of the brake discs.
Min
Max
68
MAINTENANCE AND LUBRICATION
Brakes
Brake Fluid ( Foot Brake)
Check brake fluid level before each use of the vehicle.
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 l evel
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
service.
The foot brake master
cylinder is located under the
right rear fender. View the
fluid level through the reservoir
body. F luid level i s full at the
MAX mark. Add brake fluid if the
level reaches the MIN mark.
WARNING
Once open, a bottle of brake fluid
absorbs moisture from the air, which
causes the boiling temperature of the
brake fluid to drop. This can lead to
early brake fade and the possibility of
accident. Do not store opened brake
fluid. Properly discard any unused
portion.
10-20 mm
1
69
MAINTENANCE AND LUBRICATION
Brakes
Brake Freeplay
Periodically measure the freeplay of the rear brakes. Acceptable
freeplay range is 10-20 mm.
To adjust rear brake freeplay, turn the adjuster nut (1) at the rear brake
drum.
Brake Lever Travel
Service the brakes when brake
lever travel reaches 65 mm.
Always service the brakes when
there is no longer sufficient
stopping ability at the specified
lever travel setting.
65 mm
70
MAINTENANCE AND LUBRICATION
Steering / Suspension
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. Set the handlebars in a
straight-ahead position.
2. Place stands (1) in front of the
vehicle, perpendicular 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 (2).
4. Measure the distance from the
string to the rim at the front
and rear of the front rim (3).
The rear measurement should
be 2 to 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.
Rear Springs
The rear shock absorber springs are
adjustable.
Rotate the adjuster (2) clockwise to increase
or counterclockwise to decrease spring
tension.
1
2
3
2
71
MAINTENANCE AND LUBRICATION
Steering / Suspension
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 Adju stment
1. Remove the handlebar cover.
2. Loosen (do not remove) all four
handlebar bolts.
3. Adjust the handlebar to the
desired height.
NOTE: Make sure the handlebars do
not contact the gas tank or
any part of the machine when
turned fully to the left or right.
4. Torque the t wo front bolts (1),
then torque the t wo rear bolts (2).
=14-17 N-m
NOTE: A gap of up to 3 mm should remain at the rear bolts.
WARNING
Improper adjustment of the handlebars or incorrect torquing of
the adjuster block tightening bolts can cause limited steering or
loosening of the handlebars, resulting in loss of control. Follow
the adjustment procedures exactly, or see your Polaris dealer for
service.
1
2
72
MAINTENANCE AND LUBRICATION
Carburetor Idle Adjustment
IMPORTANT: Your Polaris vehicle is calibrated at the factory for
optimal performance at altitudes ranging from zero to 1800 meters and
at temperatures of 4 degrees C. or higher. Above 1800 meters the
engine air/fuel mixture becomes too rich and the engine loses
approximately 3% of its power for each 300 meter increase in
elevation. Although this power cannot be regained, adjustments to the
carburetor and drive system can be made to allow more efficient
operation. Optional jets and clutch components, available from your
Polaris dealer, are required for operation above 1800 meters. Jetting is
required only when operating below 4 degrees C. at 1800 meters and
lower.
NOTE: Operating the engine with improper jetting can cause poor
performance, overheating or engine damage. See your
Polaris dealer for more information about jetting.
If necessary, the carburetor can be adjusted.
1. Position the vehicle on a
level surface.
2. Squeeze the brake lever.
3. Start the engine.
4. Lock the parking brake.
5. Operate the engine for about five
minutes.
6. Stop the engine.
7. Adjust the carburetor idle
screw clockwise to raise
RPM or counterclockwise to
lower RPM.
+RPM
-- R P M
1
3
2
4
2
1.6-3.2 mm
2
4
2
2
2
73
MAINTENANCE AND LUBRICATION
Throttle Cable Freeplay Adjustment
1. Locate the throttle
cable adjuster (1) on
the handlebar.
2. Slide the boots (2) off
the cable adjuster
sleeve (3). Loosen the
adjuster (4).
3. Turn the adjuster until 1. 6-3.2 mm
of freeplay exists at the lever.
NOTE: Move the throttle lever
back and forth several
times while adjusting.
4. Tighten the adjuster.
Slide the boots (2) over
the cable adjuster until
they touch at the
midpoint of the adjuster.
NOTE: Engine RPM should
not increase when
steering is turned full
left or right. Readjust
cable freeplay if this
occurs.
74
MAINTENANCE AND LUBRICATION
Wheel Removal / Installation
CAUTION
Operating with improperly installed wheels will affect vehicle
handling and could cause an accident resulting in serious injury or
death. Always use original equipment size and type when
replacing tires. Install wheels properly.
1. Position the vehicle on a
level surface.
2. Place the transmission in
gear.
3. Lock the parking brake.
4. Safely place jackstands
under the vehicle.
5. Remove the wheel nuts
and remove the wheel.
FNR
75
MAINTENANCE AND LUBRICATION
Wheel Removal / Installation
6. Place the wheel on the hub.
7. Install the wheel nuts
finger tight.
8. Carefully remove the jackstands.
9. Torque the wheel nuts.
=27 N-m
3mm
76
MAINTENANCE AND LUBRICATION
Tires
Tire Tread Depth
Always replace tires when tread
depthiswornto3mmorless.
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
beginning on page 94.
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.
Wheel and Hub Tightenin g
Wheel hub and bearing tightness and spindle nut retention are critical
items. These services must be performed by an authorized dealer.
1
77
MAINTENANCE AND LUBRICATION
Air Filter
1. Place the transmission in gear.
2. Lock the parking brake.
3. Remove the seat.
4. Unlatch the air box clips (1).
Remove the air box cover.
5. Loosen the hose clamp and
remove the filter.
6. Remove the pre-filter from the
filter. Wash the pre-filter in soapy
water. Rinse and air dry.
NOTE: Replace the filter if needed.
7. Reverse the steps to reinstall all
components.
FNR
78
MAINTENANCE AND LUBRICATION
Spark Plugs
1. Remove the spark plug cap.
2. Using the special wrench
provided in the tool
pouch, rotate the s park
plug counterclockwise to
remove.
3. Inspect the electrodes for
wear and carbon buildup.
Replace worn or fouled
plugs. Verify that the gap
is at specification before
installation.
4. Reinstall the spark plug.
=19 N-m
5. Reinstall the spark plug
cap.
79
MAINTENANCE AND LUBRICATION
Spark Plugs
Spark Plug Condition
Normal
The insulator tip is tan or brown. There are few combustion deposits.
The electrodes are not burned or eroded. This indicates the proper t ype
and heat range for the engine and the service.
NOTE: The tip should not be white. A white insulator tip indicates
overheating, caused by use of an improper spark plug or
incorrect carburetion adjustments.
Fouled
The insulator tip is black. A damp 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 consumption,
improper use of the choke, or incorrect carburetion adjustments.
Side Panel Removal
1. Remove the seat.
2. Remove the three
fasteners (1) securing
the side panel to the
vehicle.
3. Pull the side panel
away from the
vehicle.
1
80
MAINTENANCE AND LUBRICATION
Vehicle Immersion
CAUTION
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.
If your vehicle has been totally submerged in water and it’s impossible
to have it serviced before further operation, perform the following
procedure.
1. Move the vehicle out of
the water.
2. Turn the fuel valve off.
3. Remove the spark plug.
4. Drain any water found in
the air box.
81
MAINTENANCE AND LUBRICATION
Vehicle Immersion
5. Loosen the carburetor drain screw
and drain the carburetor.
6. Turn the engine over several times
using the electric start.
7. Dry the spark plug. Reinstall the
spark plug. Install a new spark plug
if necessary.
=19 N-m
8. Tighten the carburetor drain screw.
9. Turn the fuel valve on.
10. Attempt to start the engine. If
necessary, repeat the drying
procedure.
11. Have the vehicle serviced by your
dealer promptly, whether you
succeed in starting it or not.
NOTE: If water has been ingested into the transmission (CVT),
follow the procedure for drying out the CVT. See page 83.
82
MAINTENANCE AND LUBRICATION
Constant Variable Transmission (CVT) System
WARNING
Do not modify any component of the CVT system. Doing so may
reduce its strength so that a failure may occur at a high speed.
The CVT system has been precision balanced. Any modification
will cause the system to be out of balance, creating vibration and
additional loads on components.
The CVT 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:
S Always follow all recommended maintenance procedures. See
your dealer as outlined in the owner’s manual.
S This CVT system is intended for use on Polaris products only.
Do not install it in any other product.
S Always make sure the CVT housing is securely in place during
operation.
83
MAINTENANCE AND LUBRICATION
Constant Variable Transmission (CVT) System
CVT Drying
If water is ingested into the CVT system, dry it before operating t he
vehicle.
1. Place the transmission in neutral.
2. Lock the parking brake.
3. Remove the drain plug.
4. Drain the water.
5. Reinstall the drain plug.
=24 N-m
6. Start the engine.
7. Apply varying throttle for 10-15
seconds to expel t he moisture and
air-dry the belt and clutches. Do
not hold the throttle wide open.
8. Allow the engine RP M to return
to idle speed.
9. Test for belt slippage. If the belt slips, repeat the process.
10. Take the vehicle to your dealer for service promptly.
FNR
84
MAINTENANCE AND LUBRICATION
Battery
WARNING
Improperly connecting or disconnecting battery cables can cause
sparks which could result in an explosion, causing serious injury or
death. When removing the battery , always disconnect the negative
(black) cable first. When reinstalling the battery, always connect the
negative (black) cable last.
Battery Removal
1. Place the transmission in gear.
2. Lock the parking brake.
3. Remove the seat.
4. Disconnect the battery hold-down
strap.
5. Disconnect the black (negative)
battery cable first.
6. Disconnect the red (positive)
battery cable next.
7. Lift the battery out of the battery
compartment.
FNR
85
MAINTENANCE AND LUBRICATION
Battery
Battery Installatio n
1. Always install a fully
charged battery. See page 86.
2. Set the battery in the battery
holder.
3. Connect and tighten the red
(positive) cable first.
4. Connect and tighten the
black (negative) cable last.
5. Attach the hold-down strap.
6. Verify that cables are
properly routed.
7. Reinstall the seat.
86
MAINTENANCE AND LUBRICATION
Battery
Battery Storage
Whenever the vehicle is not used for a period of three months or more,
remove the battery from the vehicle. Verify 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
Tendert charger (P/N 2871076) or by charging about once a
month to make up for normal self-discharge. Battery
Tendert can be left connected during the storage period,
and will automatically charge the battery if the voltage drops
below a pre-determined point.
Battery Charging
The following battery charging instructions apply only to the
installation of an activated, sealed battery. Read all i nstructions before
proceeding with the installation of this battery.
A sealed battery is already filled with electrolyte. It has been sealed
and is fully charged at the factory. Always keep a sealed battery fully
charged.
S DO NOT pry the sealing strip off.
S DO NOT add any other fluid to this battery.
S A fully charged battery will register 12.8 V or higher.
1. Check battery voltage with
a voltmeter or multimeter.
2. If voltage is low, recharge
the battery at 1.2 amps or
less until the 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, follow
the guidelines on page 87.
87
MAINTENANCE AND LUBRICATION
Battery
Battery Charging Chart (Constant Current Charger)
State of
Charge
Voltage Action Charge Time*
(Using constant current
charger @ standard amps
specified on top of battery)
100% 12.8-13.0 v olts 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 At least 20 hours
NOTE: Always verify battery condition before and one to two hours
after charging.
WARNING
An overheated battery may explode, causing serious 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.
88
MAINTENANCE AND LUBRICATION
Lights
WARNING
Poor lighting can result in loss of control or an accident. Lights
become dirty during normal operation. Wash the headlights and
tail lights frequently.
Hot components can cause serious burns to skin. Do not service
the headlamps until they’ve cooled.
Headlight Lamp Replacement
To access the assembly from the front, remove the front cover and
unplug the wiring harness. Remove the headlight assembly from the
vehicle.
To access the headlight assembly without removing the front cover,
reach up under the front cab.
1. Remove the rubber cover
from the back of the
headlight.
2. Rotate the socket
counterclockwise and
pullitawayfromthe
headlight assembly.
3. Remove the headlamp.
4. Install the new headlamp.
5. Reinstall all components.
Tail Lig h t Replacement
1. Remove the taillight
lens cover mounting
screws.
2. Remove the lens cover.
3. Remove the lamp.
4. Apply dielectric grease to the socket and install a new lamp.
5. Test the taillight/brakelight for proper operation.
6. Reinstall the lens cover.
89
MAINTENANCE AND LUBRICATION
Cleaning the Vehicle
Keeping the vehicle clean will extend the life of components.
S Use a garden hose and a pail of mild soap and water
S Use a professional-type washing mitten, cleaning the upper body
first and the lower parts last.
S Rinse with clean water frequently.
S Wipe the vehicle dry with a chamois.
S Do not use high pressure water.
High pressure water may damage components. If a high pressure wash
system must be used, exercise extreme care to avoid directing water
onto the wheel bearings, transmission seals, body panels, brakes and
warning labels. Grease all fittings immediately after washing, and
allow the vehicle to run for a while to evaporate any water t hat may
have entered the engine or exhaust system.
NOTE: If warning and safety labels are damaged, contact your
Polaris dealer for free replacements.
Waxing the Vehicle
Wax the vehicle with any non-abrasive automotive paste wax. Avoid
harsh cleaners since they can scratch the finish.
CAUTION
Some products, including insect repellants and chemicals, will
damage plastic surfaces. Use caution when using these products
near plastic surfaces.
90
MAINTENANCE AND LUBRICATION
Storing the Vehicle
See page 93 for the part numbers of P olaris products.
Clean the Vehicle
Seepage89.
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. (Carbon Clean
Plus will reduce the possibility of bacteria l growth in the fue l
system.) Allow 15-20 minutes of operation for the stabiliz er to
disperse through the fuel in the tank and ca rburetor.
3. T urn the fuel valve off .
4. Drain the carbur etor bowl.
Change Oil and Filter
Change the oil and filter. See page 60.
Air Filter / Air Box
Inspect and clean (or replace) the pre-cleaner and air filter. Clean the air
box and drain the sedime nt tube. See page 77.
Check / Change Fluids
Inspect fluid levels and change fluids if necessary.
S Transmission
S Brake F luid
Battery Storage
Remove the battery. Make sure that it’s fully charged. See page 86.
91
MAINTENANCE AND LUBRICATION
Storing the Vehicle
Engine Fogging
Use Polaris Engine Fogging Oil. Follow label directions caref ully.
CAUTION
Starting the engine during the storage period will disturb the
protective oil film, which can lead to engine damage. Never start
the engine during the storage period.
Storage Area / Cover
1. Make sure tire pressure is at specification.
2. Using suitable supports under the frame, raise the vehicle slightly
so that the tires are not touching the ground.
3. Be sure the storage area is well ventilated.
4. Cover the mac hine with an appropr iate cover. Do not use plastic or
coa ted materia ls, as they do not allow proper ventilation to pre vent
condensa tion, corr osion and oxidation.
92
MAINTENANCE AND LUBRICATION
Transporting the Vehicle
Follow these procedures when transporting the vehicle.
1. Turn the engine off.
Remove the key to prevent
loss during transporting.
2. Place the transmission in gear.
3. Lock the parking brake.
4. Turn the fuel valve off.
5. Be sure the fuel cap, oil cap and
seat are installed correctly.
6. Attach the FRAME of the
Quadricycle to the transporting
unit securely using suitable
straps or rope.
FNR
93
POLARIS PRODUCTS
Part No. Description
Engine Lubricant
2870791 Fogging Oil (355 ml Aerosol)
2874865 Performance Synthetic 0W-50 (4-Cycle) Engine Oil (.95 l)
2874866 Performance Synthetic 0W-50 (4-Cycle) Engine Oil (3.8 l)
Gearcase / Transmission Lubricants
2873602 Premium AGL Synthetic Gearcase Lube (.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 (.95 l)
2870465 Pump for 3.8 liter jug
Grease / Specialized Lubricants
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)
2871312 Grease Gun Kit
2871329 Dielectric Grease (Nyogelt)
Additives / Miscellaneous
2872889 Brake and Clutch Cleaner
2871326 Carbon Clean Plus (355 ml)
2870652 Fuel Stabilizer (473 ml)
2870990 DOT3 Brake Fluid
2872893 Engine Degreaser
2871956 LOCTITE 565 Thread Sealant
94
SPECIFICATIONS
Capacities
Gross Vehicle Weight 326 kg
Dry Weight 179.2 kg
Fuel Capacity 9.5 liters
Engine Oil Capacity 1200 ml
Transmission Oil 550 ml
Rear Gearcase Oil 120 ml
Rear Rack 31.7 kg
Tongue Weight 13.6 kg (rear rack weight and tongue weight not
to exceed 13.6 kg)
Tow Capacity 136 kg
Turn Radius 165.1 cm unloaded
Ground Clearance 14.5 cm
Length 165.1 cm
Width 106.7 cm
Height 106.7 cm
Seat Height 81.3 cm
Wheel Base 114.3 cm
Engine & Cooling
Engine 4 Cycle, Single Cylinder
Lubrication Wet Sump
Bore x Stroke 65x59
Displacement 196 cc
Compression Ratio 9.2:1 Full Stroke
Engine Cooling Air cooled
Alternator Output (watts) 210w @ 5000 rpm
Carburetion 1 / 22 mm (VM Type)
Main Jet 108
Pilot Jet 35
Jet Needle 2MKNN-4 clip
Air Screw 1TurnOut
Ignition DC CDI
Timing 32°±2° @ 3000 RPM
SparkPlugType/Gap NGK R7HSA / 0.6-0.7 mm
95
SPECIFICATIONS
Drive System
Drive System Type Constant Variable Transmission (CVT)
Shift Type Side Lever F/N/R
Front Drive (ratio) N/A
Front Tires 21x7-10(4psi)
Rear Tires 20x10-9(4psi)
Suspension and Brakes
Front Suspension Dual A-Arm w/17.8 cm travel
Rear Suspension Mono-Shock Swing Arm w/16.5 cm travel
Shock Adjustment CAM
Rear Brake (Handlebar) Mechanical Drum
Foot Brake Hydraulic, All Wheel
Park Brake Mechanical, Rear
Features
Headlight Front Cover, Hi/Lo 35W
Taillight 12V 5W
Brake Light 12V 21W
Battery 12V 12 AH
Electric Start Standard
Speedometer Standard
Neutral Indicator Standard
Reverse Indicator Standard
Tool Kit Standard
DC Plug-In Accessory
Windshield Accessory
Jetting Chart
ALTITUDE
AMBIENT TEMPERATURE
Meters (Feet)
Below 40° F
(Below 5° C)
+40°F and above
(+5°C and above)
0-1800 (0-6000) 102 100
1800-3700 (6000-12000) 92.5 90
Clutching Chart
Altitude
Meters (Feet)
Roller Weight
Grams Each
0-1800 (0-6000) 6@14.5grams
1800-3700 (6000-12000) 6 @ 11 grams
96
TROUBLESHOOTING
Contact your Polaris dealer for service if you’re unable to identify
solutions using the following charts.
Engine Does Not Rotate
Possible Cause Solution
Tripped circuit breaker Reset circuit breaker
Low battery voltage Recharge battery to 12.5 VDC
Loose battery connections Check all connections and tighten
Loose solenoid / starter connections Check all connections and tighten
Engine Rotates, Fails to Start
Possible Cause Solution
Out o f fuel Turn fuel valve to reserve, refuel
Clogged fuel valve or filter Inspect and clean or replace
Water is present in fuel Drain the fuel system and refuel
Fuel valve is turned off Turn the fuel valve on
Old or non-recommended fuel Replace with new fuel
Fouled or defective spark plug(s) Inspect plug(s), replace if necessary
No spark to spark plug Inspect plug(s)
Crankcase filled with water or fuel Immediately see your Polaris dealer
Overuse of choke Inspect, clean and/or replace spark plugs
Clogged fuel filter Replace the filter
Low battery voltage Recharge battery to 12.5 VDC
Mechanical failure See your Polaris dealer
Engine Pings or Knocks
Possible Cause Solution
Poor quality or low octane fuel Replace with recommended fuel
Incorrect ignition timing See your Polaris dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
97
TROUBLESHOOTING
Engine Backfires
Possible Cause Solution
Weak spark from spark plugs Inspect, clean and/or replace spark plugs
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
Old or non-recommended fuel Replace with new fuel
Incorrectly installed spark plug wires See your Polaris dealer
Incorrect ignition timing See your Polaris dealer
Mechanical failure See your Polaris dealer
Engine Runs Irregularly, Stalls or Misfires
Possible Cause Solution
Fouled or defective spark plugs Inspect, clean and/or replace spark plugs
Worn or defective spark plug wires See your Polaris 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 12.5 VDC
Kinked or plugged fuel vent line Inspect and replace
Incorrect fuel Replace with reco mmended fuel
Clogged air filter Inspect and clean or replace
Electronic Throttle Control malfunction See your Polaris dealer
Other mechanical failure See your Polaris dealer
Possible Lean Fuel Mixture 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
Incorrect jetting See your Polaris dealer
Possible Rich Fuel Mixture Cause Solution
Overuse of choke Inspect, clean and/or replace spark plugs
Fuel is very high octane Replace with lower octane fuel
Incorrect jetting See your Polaris dealer
98
TROUBLESHOOTING
Engine Stops or Loses Power
Possible Cause Solution
Out o f fuel Turn fuel valve to reserve, refuel
Kinked or plugged fuel vent line Inspect and replace
Water present in fuel / old fuel Replace with new fuel
Overuse of choke Inspect, clean and/or replace spark plugs
Fouled or defective spark plugs Inspect, clean and/or replace spark plugs
Worn or defective spark plug wires See your Polaris dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
Loose ignition connections Check all connections and tighten
Low battery voltage Recharge battery / Check charging system
Incorrect fuel Replace with reco mmended fuel
Clogged air filter Inspect, clean or replace
Reverse speed limiter malfunction See your Polaris dealer
Electronic throttle control malfunction See your Polaris dealer
Other mechanical failure See your Polaris dealer
Overheated engine Clean radiator screen and core if equipped
Clean engine exterior
See your Polaris dealer
99
WARRANTY
LIMITED WARRANTY
Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a TWO YEAR LIM-
ITED WARRANTY on all components of the Polaris Quadricycle againstdefects inmateri-
al 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
thedate of purchase. This warranty istransferrable to another consumerduring thewarranty
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 QUADRI-
CYCLE SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER
TO HAVE VALID WARRANTY ON THE QUADRICYCLE. No verification of registra-
tion 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 “cus-
tomer copy”, please contact your dealer immediately. NO WARRANTY COVERAGE
WILL BE ALLOWED UNLESS YOUR QUADRICYCLE IS REGISTERED WITH PO-
LARIS.
Initial dealer preparation and set-up of your vehicle is very important in ensuring trouble-
free operation. Purchasing a machine in the crate or without proper dealer set-up will void
your warranty coverage.
LIMITATIONS OF WARRANTIES AND REMEDIES
The Polaris limited warranty excludesany 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 purposesother than for whichit wasmanufactured, orfor any damages whichoccur
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 warranty shall
be, at Polaris’ exclusive option, repair or replacement of any defective materials, or compo-
nents or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE
ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR-
RANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDEN-
TAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION,
WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTH-
ER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. So me 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.
100
WARRANTY
LIMITATIONS OF WARRANTIES AND REMEDIES
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE TWO YEAR WARRAN-
TY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT
STATED IN THIS WARRANTY. Some states do not allow limitations on how long an im-
plied warranty lasts, so the above limitation may not apply to you if inconsistent with con-
trolling state law.
HOW TO OBTAIN WARRANTY SERVICE
Ifyour Quadricycle requireswarranty service, you must take it to a Polaris dealer authorized
to repair Polaris Quadricycles. When requesting warranty service you must present your
copy of the Warranty Registration form to the dealer. (THE COST OF TRANSPORTA-
TION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests
that you useyour original selling dealer; however, you may use any Polaris Servicing Dealer
to perform warranty service.
Please work with your dealer to resolveany warranty issues. Should your dealer require any
additional assistance they will contact the appropriate personnel at Polaris.
Thiswarranty givesyou 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.
101
MAINTENANCE RECORD
DATE MILES/KM TECHNICIAN SERVICE PERFORMED / COMMENTS
102
MAINTENANCE RECORD
DATE MILES/KM TECHNICIAN SERVICE PERFORMED / COMMENTS
103
INDEX
A
Age Restriction 7..................
Air Filter 77......................
B
Battery 84-87.....................
Battery Charging 86-87..............
Battery Installation 85..............
Battery Removal 84................
Battery Storage 86, 90..............
Brake Fluid 68....................
Brake Freeplay 69.................
Brake Lever 41...................
Brake Lever Travel 69..............
Brake, Foot 43....................
Brake, Parking 43.................
Brakes 67-69......................
Break-In Period 48.................
C
Carburetor 72.....................
Cleaning the Vehicle 89.............
Clutching Chart 95.................
Cold Weather Operation (4-Cycle) 51..
Constant Variable Transmission 82-83..
Controls 38-42....................
Crankcase Emission Control System 52.
CVT 82-83.......................
CVT Drying 83...................
D
Driving Downhill 29...............
Driving in Reverse 35..............
Driving on Slippery Surfaces 27......
Driving Over Obstacles 28...........
Driving Procedures 23..............
Driving Safely 23-37................
Driving Through Water 36-37.........
Driving Uphill 30-31...............
E
Electromagnetic Interference 52.......
Electronic Throttle Control 40........
EMISSION CONTROL SYSTEMS 52.
Engine Fogging 91................
Equipment Modifications 8..........
ETC 40.........................
E
Exhaust Emission Control System 52..
Eye Protection 22..................
F
FEATURES AND CONTROLS 38-46..
Foot Brake 43....................
Fuel Safety 44....................
Fuel Stabilizer 90..................
Fuel Tank 45.....................
Fuel Valve 45.....................
G
Gear Selector 46...................
Gearcase Oil Change, Rear 66........
Gearcase Oil Check, Rear 65.........
Gearcase Specification Chart 63.......
H
Handlebar Adjustment 71...........
Hauling Cargo 24-25................
Hazard Warning 40................
Headlights 88.....................
Helmet 22.......................
Horn 40.........................
I
Immersion 80-81...................
Indicator Lights 42.................
Instruments 38-42..................
J
Jetting Chart 95...................
K
K-Turn 32.......................
Key Switch 38....................
Kick-Start Lever 47................
L
Light Switch 39...................
Lights 88........................
Load Distribution 25...............
Locking the Parking Brake 43........
Lubrication Recommendations 57.....
104
INDEX
M
Main Switch 38...................
MAINTENANCE AND
LUBRICATION 53-92..........
Maintenance Chart Key 53...........
MAINTENANCE RECORD 101-102..
Making Turns 26..................
Mirrors 41.......................
N
Noise Emission Control System 52....
O
Oil Change 60-62..................
Oil Check 59.....................
Oil Filter Change 60-62.............
Oil, Engine 58....................
OPERATION 48-51................
Operator Safety 6-17................
P
Parking Brake 43..................
ParkingonanIncline 37............
Periodic Maintenance Chart 53-56.....
POLARIS PRODUCTS 93..........
Pre-Ride Inspection 49..............
R
Rear Springs 70...................
Restrictions 8.....................
Riding Gear 22...................
S
Safe Riding Gear 22................
SAFETY 6-37.....................
Safety Decals and Locations 18-21.....
Safety Training 7..................
Severe Use 53....................
Side Panel Removal 79.............
Sidehilling 34....................
S
Spark Plugs 78-79..................
SPECIFICATIONS 94-95............
Springs, Rear 70..................
Start Switch 38....................
Starting the Engine 50-51............
Steering 70.......................
Steering Assembly 71..............
Storing the Vehicle 90-91............
Suspension 70....................
Symbol Identification 57............
T
TABLE OF CONTENTS 3..........
Tail Lights 88.....................
Throttle Cable Freeplay 73...........
Throttle lever 39..................
Tire Tread Depth 76................
Tires 76.........................
Toe Alignment 70.................
Torque Symbol 57.................
Towing 24-25.....................
Transmission Oil Change 64.........
Transmission Oil Check 63..........
Transporting the Vehicle 92..........
TROUBLESHOOTING 96-98........
Turn Indicator 41..................
Turning Around on a Hill 32-33.......
V
VEHICLE IDENTIFICATION
NUMBERS 5.................
Vehicle Immersion 80-81............
W
Warranty 99-100...................
Waxing the Vehicle 89..............
Wheel Hub Tightening 76...........
Wheel Installation 74-75.............
Wheel Removal 74-75..............
