Polaris 2001 ATV Universal User Manual

2001

Universal Owner’s Safety

and Maintenance Manual

ATV

Read this manual carefully. It contains important safety information.

This is an adult vehicle only.

Operation is prohibited for those under 16 years of age.

The engine exhaust from this

product contains chemicals known

to cause cancer, birth defects or

other reproductive harm.

WARNING

FOREWORD

Congratulations and thank you from Polaris Industries Inc. for pur-

chasing one of our all-terrain vehicles (ATVs). Built with American

engineering and manufacturing know-how, it is designed to pro-

vide superior riding comfort, enjoyment, and safety.

This manual is furnished to ensure that the operator is aware of

safe operating procedures. It also includes information about the

general care and maintenance of your ATV.

Carefully read the following pages. If you have any questions re-

garding this ATV contact a Polaris dealer for a ssistance. Remem-

ber, Polaris dealers have the knowledge and facilities to provide

you with the best service possible.

PROTECT YOUR SPORT

Know all local, state/province riding laws;

Respect your vehicle;

Respect the environment; and

You will gain the respect of others.

We also advise you to strictly follow the recommended mainte-

nance program as outlined. This preventive maintenance pro-

gram is designed to ensure that allcritical components on this ATV

are thoroughly inspected at various intervals.

All information in this manual is based upon the latest product data

and specifications available at the time of printing. Polaris Indus-

tries Inc. reserves the right to make product changes and improve-

ments which may affect illustrations or explanations.

No part of this manual shall be reproduced or used without the writ-

ten permission of Polaris Industries Inc.

Illustrations included in this manual are general

representations of parts having a similar function. Your

model may differ.

AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPER-

ATE. An ATV handles differently from other vehicles including mo-

torcycles and cars. A collision or rollover can occur quickly, even

during routine maneuvers such as turning and driving on hills or

over obstacles, if you fail to take proper precautions.

SERIOUS INJURY OR DEATH can result if you do not follow

these instructions:

• Read this manual and all labelscarefully and follow the operating

procedures described.

• Never operate an ATV without proper instruction. Take a train-

ing course. Beginners should receive training from a certified

instructor. Contact an authorized Polaris ATV dealer or call Po-

laris at 1-800-342-3764 to find out about the training courses

nearest you.

• Never allow anyone under 16 years of age to operate this ATV.

• Never permit a guest to operate this ATV unless the guest has

read this manual and all product labels, and has completed a

certified training course.

• Always avoid operating an ATVon any paved surfaces,including

sidewalks, driveways, parking lots and streets.

• Never operate an ATV on any public street, road or highway,

even a dirt or gravel one.

• Never operate an ATV without wearing an approved helmet that

fits properly. You should also wear eye protection (goggles or

face shield), gloves, boots, long-sleeved shirtor jacket, and long

pants.

• Never consume alcohol or drugs before or while operating this

ATV .

• Never operate a t excessive speeds. Always travel at a speed

which is properfor the terrain, visibility and operating conditions,

and your experience.

• Never attempt wheelies, jumps or other stunts.

• Always inspect your ATV each time you use it to make sure it is

in safe operating condition. Always follow the inspection and

maintenance procedures and schedules described in this

manual.

• Always keep both hands on the handlebars and both feet on the

footrests of the ATV during operation.

• Always go slowly and be extra careful when operating on unfa-

miliar terrain. Always be alert to changing terrain conditions

when operating the ATV.

• Never operate on excessively rough, slippery or loose terrain.

• Always follow p roper procedures for turning as described in this

manual. Practice turningat lowspeedsbeforeattempting to turn

at faster speeds. Do not turn at excessive speed.

• Always have the ATV checked by an authorized Polaris dealer

if it has been involved in an accident.

• Never operate the ATV on hills too steep for the ATV or for your

abilities. Practice on smaller hills before attempting larger hills.

• Always follow proper procedures for climbing hills as described

in this manual. Check the terrain carefully before you start up

any hill. Never climb hills with excessively slippery or loose sur-

faces. Shift your weight forward. Never open the throttle sud-

denly or make sudden gear changes. Never go over the top of

any hill at high speed.

• Always follow proper procedures for going down hills and for

braking on hills as described in this manual. Check the terrain

carefully before you start down any hill. Shift your weight back-

ward. Never go down a hill at high speed. Avoid going down a

hill at an angle which would cause the vehicle to lean sharply to

one side. Go straight down the hill where possible.

• Always follow proper procedures for crossing the side of a hill as

described in this manual. Avoid hills with excessively slippery or

loose surfaces. Shift your weight to the uphill side of the ATV.

Never attempt to turn the ATV around on any hill until you have

mastered the turning technique described in this manual on lev-

el ground. Avoid crossing the side of a steep hill if possible.

• Alwaysuse proper procedures if you stall or roll backwards when

climbing a hill. To avoid stalling, maintain a steady speed when

climbing a hill. If you stall or roll backwards, follow the special

procedureforbraking describedin thismanual. Dismount on the

uphill side or to either side if pointed straight uphill. Turn the ATV

around and remount, following the procedure described in this

manual.

• Always check for obstaclesbefore operating in a new area. Nev-

er attempt to operate over large obstacles, such as large rocks

or fallen trees. Alwaysfollow proper procedures when operating

over obstacles as described in this manual.

• Always be careful of skidding or sliding. On slippery surfaces,

such as ice, go slowly and be very cautious in order to reduce

the chance of skidding or sliding out of control.

• Avoid operating the ATV through deep or fast flowing water. If

you cannot avoid water which exceeds the recommended maxi-

mum depth (pg. NO TAG), go slowly, balance your weight care-

fully avoiding sudden movements, maintain a slow and steady

forward motion, do not make sudden turns or stops, and do not

make sudden throttle changes.

• Wet brakes may have reduced stopping ability. Test your brakes

after leaving water. If necessary apply them lightly severaltimes

to let friction dry out the pads.

• Always be sure there are no obstacles or people behind you

when you operate in reverse. When it is safe to proceed in re-

verse, go slowly. Avoid turning at sharp angles in reverse.

• Always use the size and type tires specified in this manual. Al-

ways maintain proper tire pressure as described in this manual.

• Never modify an ATV through improper installation or use of ac-

cessories.

• Never exceed the stated load capacity for an ATV. Cargo should

be properly distributed and securely attached. Reduce speed

and followinstructions inthis manualfor carryingcargo or pulling

a trailer. Allow greater distance for braking.

FOR MORE INFORMATION ABOUT ATV SAFETY, call the Con-

sumer Product Safety Commission at 1-800-638-2772, or Polaris

at 1-800-342-3764.

Additional Important Information...

Due to our concern for the safety of our customersand the general

public, Polaris hereby strongly recommends and requests that

consumers not have installed on a Polaris ATV any equipment

which is intended to increase the speed or power of the vehicle; or

make any other modifications to the vehicle for these purposes.

Any modificationsto the original equipmentof the ATV substantial-

ly increase the risk of bodily injury. Please be aware that these

modifications may create a substantial safety hazard.

Polaris hereby informs you that the warranty on your ATV is termi-

nated if any such equipment has been added to the ATV or any

modifications have been made to the ATV which increase its

speed or power.

We also advise you to strictly follow the recommended mainte-

nance program outlined in this manual. This preventive mainte-

nance program is designed to ensure that all critical components

on the ATV are thoroughly inspected by your dealer at various

mileage intervals.

NOTE:

The addition of certain accessories including (but not limited to)

mowers, blades, tires, sprayers, or large racks may change the

handling characteristics of the ATV.

Be certain any accessories added to this ATV have been approved

by Polaris.

Familiarize yourself with their function and affect on the ATV.

The Polaris Preferred

Registered Owners

(PRO) Family

Your Owners Program

As the owner of a new Polaris vehicle, you are entitled to a FREE

two- year membership in the Polaris PRO Family--- the Preferred

Registered Owners Family. It’s an owners program for Polaris

owners like you, people who have chosen the finest recreational

vehicle available, people who share an interest in Polaris and its

products.

Once your new vehicle’s warranty is registered, you will receive a

PRO Family membership packet that will include:

A letter of welcome to the PRO Family

A PRO Family card with your name and membership number

A colorful sticker of the PRO logo

A PRO merchandise brochure and order form.

As a PRO Family member, you’re entitled to opportunities such as:

A free subscription to PRO Spirit, the official magazine of the

PRO Family

The chance to buy insurance for your Polaris vehicle. The toll-

free insurance telephone number is: 1-800-473-0111

The chance to arrange travelthrough the Polaris TravelCenter.

The toll-free travel telephone number is: 1-800-267-1915

The chance to apply to serve on PRO Consumer Councils that

provide input into the Polaris vehicles of the future

The chance to serve as a PRO Field Evaluator and provide

feedback on your new vehicle

The chance to take part in national PRO snowmobile, ATV or

personal watercraft rides

The chance to purchase exclusive PRO Family merchandise

And more!

To order PRO merchandise, complete the order form you receive

with your membership packet, take the form to your Polaris dealer

and pay for the merchandise. The merchandise will be shipped di-

rectly to your home from the PRO merchandise fulfillment center.

Watch for your PRO membership packet and the next issue of

PRO Spirit magazine. This quarterly magazine will keep you in-

formed about Polaris news and events, and special PRO mer-

chandise, travel, and ride opportunities.

Enjoy your new Polaris vehicle, and welcome to the family--The

Polaris PRO Family.

CONTENTS

UNDERSTANDING WARNINGS 1-2..........................

SAFETY WARNING AND OPERATION DECALS 3-11...........

DAILY PRE-RIDE INSPECTION 12...........................

OPERATION W ARNINGS 13-33..............................

VEHICLE IDENTIFICATION NUMBERS 34.....................

CONTROL AND PAR TS FUNCTIONS 35-65...................

STARTING T HE ENGINE 66.................................

VEHICLE BREAK IN PERI OD 67-69..........................

RIDING GEAR 70...........................................

CARRYING LOADS 71-73...................................

DAILY PRE-RIDE INSPECTION 74...........................

RIDING 75-88..............................................

PVT System 89-91..........................................

BATTERY 92-94............................................

NOISE EMISSION CONTROL SYSTEM REGULATION 95.......

MAINTENANCE 96-168.....................................

TROUBLE SHOOTING 167-172.............................

W ARRANTY 173-175.......................................

INDEX 176-177............................................

UNDERSTANDING WARNINGS

ATTENTION:

This is an ADULT VEHICLE ONLY; not a toy. Operation is prohib-

ited for anyone under 16 years of age. READ ANDUNDERSTAND

WARNINGS AND OWNER’S MANUAL BEFORE OPERATION.

KNOW YOUR VEHICLE BEFORE YOU BEGIN RIDING!.

Read this manual thoroughly referring to the various areas which

are being discussed on your machine. Operating this vehicle car-

ries with it responsibilities for your personal safety, the safety of

others, and the protection of our environment.

SAFETY TRAINING.

When you purchased this vehicle your dealer presented a hands-

on safety training course covering all aspects of ATV safety. In

addition, you were provided with certain printed material which

instructs you on safe operating procedures.

You should review this information on a regular basis. In the event

youpurchaseda usedPolarisATVfrom a party other than a Polaris

dealer, you can obtain this safety training at no charge from any

authorized Polaris dealer.

Failure to follow the warnings contained in this manual can result

in SEVERE INJURY OR DEATH.

NOTE: Illustrations used in this manual are for general represen-

tation only. Your model may differ.

UNDERSTANDING WARNINGS

SAFETY ALERT

WARNINGS identify special instructions or procedures

which, if not correctly followed, could result in personal inju-

ry, or loss of life. Read all WARNINGS in this manual carefully.

Follow their instructions to remain safe.

The following precautionary signal words are used throughout this

manual to convey the following messages:

This is the safety alert symbol. When you

see this symbol on your machine or in this

manual, be alert to the potential for personal

injury. Your safety is involved!

Indicates a p o t en tial hazard which co u ld result in

severe injury or death.

Indicates a potential hazard which may result in mi-

nor personal injury or damage to the ATV.

NOTE

The word “NOTE:” in this manua l will

alert you to key information o r

instructions.

Indicates a situation that can result in damage to

the machine.

SAFETY WARNING AND OPERATION DECALS

NOTE:

Warning decals have been placed on the vehicle for your protec-

tion. Read and follow the instructions on each decal carefully. In

the event any decal becomes illegible or comes off, contact your

Polaris dealer for a replacement. Any safety decal needing re-

placement will be provided by Polaris at no charge. The part num-

ber is printed on the decal.

SAFETY WARNING AND OPERATION DECALS

7079083

E1997

IF OWNER’S MANUAL IS MISSING, CONTACT

YOUR POLARIS DEALER FOR A REPLACEMENT.

WARNING

SAFETY WARNING AND OPERATION DECALS

F Never operate this ATV on HILLS steeper than 25 degrees

To prevent flipover on hilly terrain, when going up or down,

use throttle and brakes gradually.

25°

F REVERSE operation can be dangerous even at low speeds.

Steering becomes difficult. To prevent flipover, avoid sudden

braking or sharp turns.

F Use OVERRIDE for reverse speed limiter with caution. To prevent

loss of control, never activate override button with open throttle.

F PARKING BRAKE may relax when used for more than 5 minutes.

When parking on grades, leave shift in forward.

7079085

Operating this ATV if you are under the age

of 16 increases your chance of severe injury

or death.

NEVER operate this ATV if you are under

age 16.

7078253

UNDER

WARNING

SAFETY WARNING AND OPERATION DECALS

(Refer to your Owner’s Manual Supplement for your vehicle’s

specifications.)

IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of

control resulting in SEVERE INJURY OR DEATH.

TIRE PRESSURE (PSI): FRONT ___ REAR ___

MAXIMUM WEIGHT CAPACITY (Gross V ehicle Weight)

INCLUDING MACHINE, DRIVER AND CARGO IS ____ LBS.

Reduce speed and allow greater distance for braking when carrying

cargo. Overloading or carrying tall, off-center, or unsecured loads

will increase your risk of losing control. Loads should be centered,

carried as low as possible, and firmly secured to the racks. with

dual racks, load distribution 1/3 front 2/3 rear is best. For stability

on rough or hilly terrain, reduce speed and cargo. Do not block

headlight. Be careful if load extends over the side of the rack.

Read Owner’ s Manual for more detailed loading information

(on rear of seat)

WARNING

SAFETY WARNING AND OPERATION DECALS

ATTENTION

DOPERA TION OF THIS VEHICLE WITHOUT

THE FILTER ELEMENT WILL SEVERELY

DAMAGE THE ENGINE.

DCLEAN AIR FILTER OFTEN, MORE FRE-

QUENT CLEANING REQUIRED IN

DUSTY CO NDITIONS.

DLiutilisation de ce véhicule sous liélément

filtre endommage sévèrement le moteur.

DNettoyer souvent le filtre à air, surtout dans

des situations poussiereuses.

7072791

(Under Seat)

Moving parts hazard under belt-clut ch guard. To

prevent ser ious injur y, do not operat e vehic le wit h

guard removed.

Do not modify engine or clutch. Doing so can cause part

failure, possible imbalance, and excessive engine RPM

which can result in serious injury or death.

NO STEP

7078689

WARNING

SAFETY WARNING AND OPERATION DECALS

DO NOT TOW FRO M RACK O R BUM PER.

vehicle damage or t ipover may r esult causing severe

injury or death. Tow only fr om t ow hook s or hitc h.

Maximum Front Rack Load 90 lbs.

7079102

DO NOT TOW FRO M RACK O R BUM PER.

vehicle damage or t ipover may r esult causing severe

injury or death. Tow only fr om t ow hook s or hitc h.

Maximum Rear Rack Load 180 lbs.

7079110

WARNING

SAFETY WARNING AND OPERATION DECALS

ALL WHEEL

DRIVE

SWITCH

Do not push switch to

engage AWD if the rear

wheels are spinning.

This may cause severe

drive shaft and clutch

damage.

See y our Owner’s

Manual.

7074935

MANUFACTURED

BY: POLARIS IND

DATE:

VIN:

THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND

IS NOT INTENDED FOR USE ON PUBLIC ROADS.

PRINTED IN U.S.A.

7077185

CE VÉHICULE EST UN VÉHICULE TOUT TERRAIN

QUI NiEST PAS DESTINÉ À ÊTRE UTILISÉ SUR

LES CHEMINS PUBLICS.

ATTENTION

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 26° C. at 0-900 meters). 7073761

TRAILER MAX.

WEIGHT 850 LBS.

HITCH MAX. VERTICAL

WEIGHT 30 LBS.

POIDS MAX. DE

REMORQUE 386 KG.

POIDS MAX.

VERTICAL D’ATTACHE

14 KG.

OVERRIDE

SWITCH

Reverse override

and all wheel drive

activation in reverse

is controlled by the

override switch.

See your Owner’s

Manual.

7076273

Reverse Speed is

limited.

Reverse override is

controlled by the

override switch.

See your Owner’s

Manual.

OVERRIDE

SWITCH

7076274

AWD Models 2WD Models

7077542

TRAILER MAX WEIGHT:

1225 LBS. (556 KG) ON LEVEL GROUND

850 LBS. (368 KG) UP TO 15° GRADE

HITCH MAX. VERTICAL W EIGHT: 35 LBS. (16KG)

7072533

Chain Freeplay Is Important.

Adjust Freeplay to 3/16″ -- 3 / 8 ″

DO NOT Overtension. See

Owner’s Manual .

Torque Nut on Eccentric Bolts:

To 30 Ft. Lbs.(For model s

without a hitch).

To 60 Ft. Lbs. (For models with

ahitch.

7078572

DAILY PRE-RIDE INSPECTION

Use the following checklist to verify your machine is in properwork-

ing order each time you ride.

Item/Inspection Procedure

1. Tires - check condition and pressures

2. Fuel and oil tanks - fill both tanks to their proper levels

3. All brakes - check operation, adjustment and fluid level (in-

cludes auxiliary brake)

4. Throttle - check for free operation and closing

5. Headlight/Taillight/Brakelight - check operation of all indicator

lights and switches

6. Engine stop switch - check for proper function

7. Wheels- checkfor tightnessof wheelnuts and axle nuts; check

that axle nuts are secured by cotter p ins

8. Drive chain - condition and slack; refer to drive chain adjust-

ment

9. Air cleaner element - check for dirt; clean or replace

10. Steering - check for free operation noting any unusual loose-

ness in any area

11. Loose parts - visually inspect vehicle for any damaged compo-

nents or loose nuts/bolts or fasteners

12. Operators helmet, goggles and clothing

13. Engine coolant - (Liquid Cooled Models Only) check for proper

level at the recovery bottle

You must inspect your ATV each time before riding to ensure

it is in proper working order. If proper inspection is not done,

severe injury or death could result.

OPERATION WARNINGS

POTENTIAL HAZARD

Operating this ATV without proper instruction.

WHAT CAN

HAPPEN

The risk of an accident is greatly increased if the operator

does not know how to operate the ATV properly in differ-

ent situations and on different types of terrain.

HOW TO AVOID THE

HAZARD

Beginning and inexperienced operators should complete

the certified training course offered by Polaris Industries

Inc. They should then regularly practice the skills learned

in the course and the operating techniques described in

the Owner ’s Manual.

For more information about the training course, contact

an authorized ATV dealer or call Polaris at

1-800-342-3764.

POTENTIAL

HAZARD

Failure to follow the age recommendations for this ATV.

WHAT CAN

HAPPEN

Use by children of ATVs that are not recommended for

their age can lead to severe injury or death of the child.

Even though a child may be within the age group for

which some ATVs are recommended, he or she may not

have the skills, abilities, or judgment needed to operate

the ATV safely and may be involved in a serious acci-

dent.

HOW TO AVOID THE

HAZARD

No one under 16 should operate a Polaris ATV.

WARNING

OPERATION WARNINGS

POTENTIAL HAZARD

Carrying a passenger on this ATV.

WHAT CAN

HAPPEN

Greatly reduces your ability to balance and control this

ATV .

Could cause an accident, resulting in harm to you and/or

your passenger.

HOW TO AVOID THE

HAZARD

Never carry a passenger. The long seat is to allow the op-

erator to shift position as needed during operation. It is not

for carrying passengers.

WARNING

OPERATION WARNINGS

POTENTIAL HAZARD

Operating this ATV on paved surfaces, including side-

walks, paths, parking lots, and driveways.

WHAT CAN

HAPPEN

The ATV tires are designed for off-road use. Paved

surfaces may seriously affect handling and control of

the ATV, and may cause the vehicle to go out of control.

HOW TO AVOID THE

HAZARD

Avoid operating the ATV on pavement whenever pos-

sible. If you must ride on a paved surface,go slowly and

do not make sudden turns or stops.

WARNING

OPERATION WARNINGS

POTENTIAL HAZARD

Operating this ATV on public streets, roads or high-

ways.

WHAT CAN

HAPPEN

You can collide with another vehicle.

HOW TO AVOID THE

HAZARD

Never operate this ATV on any public street, road or

highway, even a dirt or gravel one.

In many states it is illegal to operate ATVs on public

streets, roads and highways.

WARNING

OPERATION WARNINGS

POTENTIAL HAZARD

Operating this ATV without wearing an approved helmet,

eye protection and protective clothing.

WHAT CAN

HAPPEN

Operating without an approved helmet increases your

chances of a severe head injury or death in the event of

an accident.

Operating without eye protection can result in an accident

and increasesyour chancesof a severe injury in the event

of an accident.

HOW TO AVOID THE

HAZARD

Always wear an approved helmet which fits properly.

You should also wear: eye protection (goggles or face

shield); gloves; boots; long-sleeved shirt or jacket; and

long pants.

WARNING

OPERATION WARNINGS

POTENTIAL HAZARD

Operating this ATV after consuming alcohol or drugs.

WHAT CAN

HAPPEN

Could seriously affect your judgment.

Could cause you to react more slowly.

Could affect your balance and perception.

Could result in an accident.

HOW TO AVOID THE

HAZARD

Neverconsume alcohol or drugs before or while driving

this ATV.

POTENTIAL

HAZARD

Operating this ATV at excessive speeds.

WHAT CAN

HAPPEN

Increases your chances of losing control of the ATV,

which can result in an accident.

HOW TO AVOID THE

HAZARD

Always travel at a speed which is proper for the terrain,

visibility and operating conditions; and your experi-

ence.

WARNING

OPERATION WARNINGS

POTENTIAL HAZARD

Attempting wheelies, jumps and other stunts.

WHAT CAN

HAPPEN

Increases the chance of an accident, including an over-

turn.

HOW TO AVOID THE

HAZARD

Never attempt stunts, such as wheelies or jumps. Don’t

try to show off.

WARNING

OPERATION WARNINGS

POTENTIAL HAZARD

Failure to inspect the ATV before operating.

Failure to properly maintain the ATV.

WHAT CAN

HAPPEN

Increases the possibility of an accident or equipment

damage.

HOW TO AVOID THE

HAZARD

Always inspect your ATV each time you use it to make

sure the ATV is in safe operating condition.

Always follow the inspection and maintenance proce-

dures and schedules described in the Owner ’s Manual.

POTENTIAL

HAZARD

Removing hands from handlebars or feet from foot-

rests during operation.

WHAT CAN

HAPPEN

Removing even one hand or foot can reduce your abil-

ity to control the ATV or could cause you to lose your

balance and fall off the ATV. If you remove a foot from

the footrest, your foot or leg may come into contact with

the rear wheels, which could injure you or cause an ac-

cident.

HOW TO AVOID THE

HAZARD

Always keep both hands on the handlebars and both

feet on the footrests of your ATV during operation.

WARNING

OPERATION WARNINGS

POTENTIAL HAZARD

Failure to use extra care when operating this ATV on un-

familiar terrain.

WHAT CAN

HAPPEN

You can come upon hidden rocks, bumps,or holes,with-

out enough time to react.

Could result in the ATV overturning or going out of con-

trol.

HOW TO AVOID THE

HAZARD

Go slowly and be extra careful when operating on unfa-

miliar terrain.

Always be alert to changing terrain conditions when op-

erating the ATV.

WARNING

OPERATION WARNINGS

POTENTIAL HAZARD

Failure to use extracare when operating on excessively

rough, slippery or loose terrain.

WHAT CAN

HAPPEN

Could cause loss of traction or vehicle control, which

could result in an accident, including an overturn.

HOW TO AVOID THE

HAZARD

Do not operate on excessively rough, slippery or loose

terrain until you have learned and practiced the skills

necessary to control the ATV on such terrain.

Always be especially cautious on these kinds of terrain.

WARNING

OPERATION WARNINGS

POTENTIAL HAZARD

Turning improperly.

WHAT CAN

HAPPEN

ATV could go out of control, causing a collision or over-

turn.

HOW TO AVOID THE

HAZARD

Always follow proper procedures for turning as de-

scribed in the Owner’s Manual. See page 76 .

Practice turning at low speeds before a ttempting to turn

at faster speeds.

Do not turn at excessive speed.

POTENTIAL

HAZARD

Operating on excessively steep hills.

WHAT CAN

HAPPEN

The vehicle can overturn more easily on extremely steep

hills than on level surfaces or small hills.

HOW TO AVOID THE

HAZARD

Never operate the ATV on hills too steep for the ATV or

for your abilities.

Practice on smaller hills before attempting large hills.

Never operate ATV on hills steeper than 25_.

WARNING

OPERATION WARNINGS

POTENTIAL HAZARD

Climbing hills improperly.

WHAT CAN

HAPPEN

Could cause loss of control or cause ATV to overturn.

HOW TO AVOID THE

HAZARD

Always follow proper procedures for climbing hills as de-

scribed in the Owner’s Manual. See pages 79 through 82.

Always check the terrain carefully before you start up any

hill.

Never climb hills with excessively slippery or loose surfaces.

Shift your weight forward.

Never open the throttle suddenly. The ATV could flip over

backwards.

Never go over the top of any hill at high speed. An obstacle,

a sharp drop, or another vehicle or person could be on the

other side of the hill.

WARNING

OPERATION WARNINGS

POTENTIAL HAZARD

Going down a hill improperly.

WHAT CAN

HAPPEN

Could cause loss of control or cause ATV to overturn.

HOW TO AVOID THE

HAZARD

Always follow proper procedures for going down hills as

described in the Owner’s Manual. See page 81. NOTE:

A special technique is required when braking as you go

downhill.

Always check the terrain carefully before you start down

any hill.

Shift your weight backward.

Never go down a hill at high speed.

Avoid going down a hill at an angle which would cause the

vehicle to lean sharply to one side. Go straight down the

hill where possible.

WARNING

OPERATION WARNINGS

POTENTIAL HAZARD

Improperly crossing hills or turning on hills.

WHAT CAN

HAPPEN

Could cause loss of control or cause ATV to overturn.

HOW TO AVOID THE

HAZARD

Never attempt to turn the ATV around on any hill until you

have mastered the turning technique as described in the

Owner’s Manual on level ground. See page 82. Be very

careful when turning on any hill.

Avoid crossing the side of a steep hill if possible.

When crossing the side of a

hill:

Always followproper proceduresas describedin the Owner ’s

Manual.

Avoid hills with excessively slippery or loose surfaces.

Shift your weight to the uphill side of the ATV.

WARNING

OPERATION WARNINGS

POTENTIAL HAZARD

Stalling, rolling back-

wards or improperly

dismounting while

climbing a hill.

WHAT CAN

HAPPEN

Could result in ATV overturning.

HOW TO AVOID THE

HAZARD

Maintain steady speed when climbing a hill.

Ifyouloseallforward

speed:

Keep weight uphill.

Apply the brakes.

Lock parking brake after you are stopped.

If you begin rolling

backwards:

Keep weight uphill; never apply engine power.

Never apply the rear brake while rolling backwards.

Apply the single-lever brake gradually.

When fully stopped, apply rear brake as well, and then lock

parking brake.

Dismount on uphill side, or to either side if pointed straight

uphill.

Turn the ATV around and remount, following the procedure

described in the Owner’s Manual. See page 82.

WARNING

OPERATION WARNINGS

POTENTIAL HAZARD

Improperly operating over obstacles.

WHAT CAN

HAPPEN

Could cause loss of control or a collision. Could cause the

ATV to overturn.

HOW TO AVOID THE

HAZARD

Before operating in a new area, check for obstacles.

Use extreme caution when riding over large obstacles, such

as large rocks or fallen trees.

If you cannot avoid obstacles, always follow proper proce-

dures as described in the Owner’s Manual.

POTENTIAL

HAZARD

Skidding or sliding.

WHAT CAN

HAPPEN

You may lose control of the ATV.

You may also regain traction unexpectedly, which may

cause the ATV to overturn.

HOW TO AVOID THE

HAZARD

On slippery surfaces, such as ice, go slowly and be verycau-

tious in order to reduce the chance of skidding or sliding out

of control.

WARNING

OPERATION WARNINGS

POTENTIAL HAZARD

Operating this ATV through deep or fast flowing water.

WHAT CAN

HAPPEN

Tiresmay float, causing loss of traction and loss of control,

which could lead to an accident.

HOW TO AVOID THE

HAZARD

Avoid operating the ATV through deep or fast flowing wa-

ter. If you cannot avoid water which exceeds the recom-

mended maximum depth (pg 83), go slowly, balance your

weight carefully avoiding sudden movements, maintain a

slow and steady forward motion, do not make sudden

turns or stops, and do not make sudden throttle changes.

Remember that wet brakes may have reduced stopping

ability. Test your brakes after leaving water. If necessary,

apply them several times to let friction dry out the pads.

POTENTIAL

HAZARD

Improperly operating in reverse.

WHAT CAN

HAPPEN

You could hit an obstacle or person behind you, resulting

in severe injury.

HOW TO AVOID THE

HAZARD

When you select reverse gear, make sure there are no ob-

stacles or people behind you. When it is safe to proceed,

go slowly.

WARNING

OPERATION WARNINGS

POTENTIAL HAZARD

Operating this ATV with improper tires, or with improper

or uneven tire pressure.

WHAT CAN

HAPPEN

Use of improper tires on this ATV, or operation of this

ATV with improper or uneven tire pressure, may cause

loss of control, and increases the risk of an accident.

HOW TO AVOID THE

HAZARD

Always use the size and type tires specified in the Own-

er ’s Manual Supplement for this vehicle.

Always maintain proper tire pressure as described in the

Owner’s Manual Supplement.

POTENTIAL

HAZARD

Operating this ATV with improper modifications.

WHAT CAN

HAPPEN

Improper installation of accessories or modification of this

vehicle may cause changes in handling which in some sit-

uations could lead to an accident.

HOW TO AVOID THE

HAZARD

Nevermodifythis ATV through improperinstallation oruse

of accessories. Allparts and accessories added to this ve-

hicle should be genuine Polaris Industries Inc. or equiva-

lent components designed for use on thisATV; and should

be installed and used according to instructions. If you

have questions, consult an authorized PolarisATV dealer.

WARNING

OPERATION WARNINGS

POTENTIAL HAZARD

Overloading this ATV or carrying or towing cargo im-

properly.

WHAT CAN

HAPPEN

Could cause changes in vehicle handling which could

lead to an accident.

HOW TO AVOID THE

HAZARD

Never exceed the stated load capacity for this ATV.

Cargo should be properly distributed and securely at-

tached.

Reduce speed when carrying cargo or pulling a trailer.

Allow greater distance for braking.

Always followthe instructionsin the Owner’sManualfor

carrying cargo or pulling a trailer. See pages 71 and 73.

POTENTIAL

HAZARD

Riding on frozen lakes and rivers.

WHAT CAN

HAPPEN

Severe injury or death can result if the ATV and/or the opera-

tor break through the ice.

HOW TO AVOID THE

HAZARD

Never ride your ATV on a frozen body of water before you

are sure the ice is thick enough and sound enough to sup-

port the machine and its operator, as well as the force that

is created by a moving vehicle.

WARNING

OPERATION WARNINGS

POTENTIAL HAZARD

Improperly operating over obstacles.

WHAT CAN

HAPPEN

Could cause loss of control or a collision. Could cause the

ATV to overturn.

HOW TO AVOID THE

HAZARD

Before operating in a new area, check for obstacles.

Use extreme caution when riding over large obstacles, such

as large rocks or fallen trees.

If you cannot avoid obstacles, always follow proper proce-

dures as described in the Owner’s Manual.

POTENTIAL

HAZARD

Skidding or sliding.

WHAT CAN

HAPPEN

You may lose control of the ATV.

You may also regain traction unexpectedly, which may

cause the ATV to overturn.

HOW TO AVOID THE

HAZARD

On slippery surfaces, such as ice, go slowly and be verycau-

tious in order to reduce the chance of skidding or sliding out

of control.

WARNING

OPERATION WARNINGS

After a rollover oran accident,have a qualified service dealer

check the complete machine including, but not limited to,

brakes, throttle and steering for possible damage.

Safe operation of this rider active vehicle requires good

judgement and physical skills. Persons with cognitive or

physical disabilities who operate this vehicle have an

increased risk of overturns and loss of control which

could result in severe injury or death.

WARNING

CAUTION: Keep combustible materials away from exhaust sys-

tem. Fire may result.

VEHICLE IDENTIFICATION NUMBERS

Record these numbers from your ATV in the spaces provided.

1. Frame VIN (found on the lower left side of the

frame tube)

2. Engine Serial Number (Right front side of engine

crankcase)

Remove the spare key and store in a safe place. Your keycan

be duplicated only by obtaining a key blank from Polaris and

having it cut by mating it with your existing key.

The vehicle frame and engine serial numbers are important for

model identification when registering your vehicle, obtaining in-

surance or whenever replacement parts are required. In the

event your vehicle were stolen these numbers are essential to

the recovery and identification of your ATV.

Dealer Imprint

CONTROL AND PARTS FUNCTIONS

Engine Electrical Switches

1. Override Switch (Reverse

Speed Limiter) - This vehicle is

equipped with a reverse speed lim-

iter system. To obtain additional

power while backing up, depress

the override button. WARNING:

Never activate the override button

while throttle is open as loss of control may result, causing severe

personal injury or death. NOTE: The override switch also allows

activation of Demand 4 Drive (All Wheel Drive) in reverse, if De-

mand 4 Drive switch is on.

2. Main Switch - This key switch must be turned clockwise to the

“on” position to start the engine (includes start feature on some

models.).

3. Emergency Engine Stop Switch - The engine will not start or

run when the switch is in its “off” position. Its purpose is to provide

the operator with a quick means of engine shutdown in case of

stuck throttle or other emergency. NOTE: Both the main switch

and the emergency engine stop switch shut off all electrical power

to the entire vehicle including lights. To stop the engine, slide the

stop switch right or left to the “off” position.

4. Engine Start Button - To start the engine, slide the stop switch

to the center “run” position and push up. Some models start by

turning the main key switch clockwise past the “on” position.

RUN

OFFOFF

CONTROL AND PARTS FUNCTIONS

Important Safeguards

D Always back slowly avoiding excessive speed and do not

use the reverse speed override switch system unless addi-

tional power is required for vehicle movement.

D Avoid turning at sharp angles in reverse.

D Avoid backing on steep inclines.

Light Switches and Indicator Lights

Switches

The light switch is located on the left hand handlebar. In addition

to turning the lights on and off, it also switches the lights from Hi

to Lo on models equipped with Hi-Lo beams. NOTE: Will not light

unless the main switch is on.

Backing your ATV can be dangerous!

You could hit an obstacle or person behind you; or the ve-

hicle could tip over rearward on a steep incline causing se-

vere injury or death.

This ATV is not equipped with highway approved lighting. This

ATV is designed for off-road use only and must not be ridden

on streets or highways. Use caution and drive at reduced

speeds in conditions of reduced visibility such as fog, rain and

darkness.

CONTROL AND PARTS FUNCTIONS

Indicator Lights

Each Polaris ATV has indicator lights. The configuration of these

lights d iffers with individual models and not every model is

equipped with all the lights. The information in your Owner’s

Manual Supplement and in the following box will help you identify

the lights on your machine and their function.

1.Transmission Neutral

(Green)

2. Transmission Reverse

(Yellow)

3. Oil Warning (Red) On 2

cycle models, this light in-

dicates a low oil level.

4. High Temp (Red) (Will light

only if engine overheats)

5. All Wheel Drive (Red) (lo-

cated on the LH handle-

bar) Refer to page 52.

6. High Beam Indicator

(Blue) (located on the LH

switch on models

equipped with Hi-Lo beam

lights)

With engine running, verify function of indicator lights each time

ATV is used.

NOTE: The taillight is on whenever the main switch (key) is in the

on position. Turn the key off to prevent battery drain.

CONTROL AND PARTS FUNCTIONS

Electronic Speedometer

Some Polaris ATVs are equipped with an electronic speedometer

which senses vehicle speed from the right hand front wheel. The

electronic speedometer measures distance in miles and kilome-

ters as well as hours of operation. The speedometer also includes

a reverse speed limit function that limits the ATV’sspeed inreverse

after approximately 7 to 9 mph. Refer to page 35 for additional in-

formation.

To display each mode, press the button on the face of the

speedometer once to “toggle” through the functions. Each func-

tion will be displayed as follows:

Miles 00000.0 M

Trip Miles 000.0 M

Hours 00000.0 H

To reset Trip Miles:

1. Toggle to Trip Miles

2. Hold down button approximately 4 seconds.

The speedometer also has additional features accessed through

a sub-menu. These features are:

D Programmable service reminder based on hours

D Programmable service reminder based on distance

D Change distance measurement from Miles to Kilometers or

vice versa.

Each service reminder is set to zero and must be programmed to

activate the feature. One or both service reminders can be set.

Whichever setting is reached first, the reminder will turn on in the

LCD window.

Do not wash the electronic speedometer with a high pressure

washer. Wash the unit by hand or with a garden hose. High

water pressure may allow water to enter the speedometer

and cause damage to the electronic components

CONTROL AND PARTS FUNCTIONS

When the programmed hours are reached, SEr hr will light; when

the programmed distance is reached, SErdIS will light. Each time

the vehicle is started, the reminder will turn on and remain lit until

the button is pushed or the speedometer is reprogrammed for the

next service interval.

Accessing Sub-menu Featu res

There are two methods for accessing the sub menu:

1. Press and hold the button and turn the power on

2. Press and hold the button for 8 seconds

Hold the button until the display shows POLArS then release the

button. The speedometeris now in the sub-menu. To displayeach

mode, press the button once to scroll through the four available

functions. Each function will be displayed as follows:

Service Hours SET hr

Service Distance SETdIS

Miles to Kilometers COnvrT

No Menu Changes DOnE

Changing Distance Measurement

1. Access the sub-menu

2. Select COnvrT and release the button. If the last digit in the

odometer display is K, the current measurement is kilometers;

if the last digit is M, distance is being measured in miles.

To Set Service Hours

1. Access the sub--menu

2. Toggle to SET hr, then release the button.

3. In 3 seconds, the LCD will display 5 digits, with the left--most

digit flashing.

4. Within 4 seconds, press and release the button to change the

digit. Once the digit is changed once, the button may be held

to scroll through the digits from 0 to 9.

5. After the digit has been selected, do not push the button. After

4 seconds the next digit will flash.

CONTROL AND PARTS FUNCTIONS

Setting Service Hours (cont.)

6. Repeatstep 4 and 5 to program the digitsforthe serviceinterval

selected. (i.e. for service interval of 50 hours set the display to

show: 00050 H)

7. To save the changes press and hold the button when any one

of the digits is flashing.

8. The display will change to DOnE. Atthis timerelease the button

and the changes are now saved.

TO CHECK WHEN SERVICE IS DUE BY HOURS

Using the 50-- hour service setting example from above, the

speedometer will take the 50--hour setting and add it to the val-

ue of the hour--meter. This will be the value displayed when the

operator checks when service is due for the ATV. For example,

the hour meter reading is 132 hours, and the service interval

was set for 50 hours, the 5-- digit display will show 182 hours.

1. Access the sub--menu

2. Toggle to SET hr , then release the button

3. In 3 seconds, the LCD will display 5 digits, with the left--most

digit flashing. As in the example above, the display would show

00182 H.

4. Either turn the power off or not touch the button for 35 seconds

to maintain the current settings.

CONTROL AND PARTS FUNCTIONS

TO SET SERVICE DISTANCE

Same as setting Service Hours, but toggle to SET dIS.

TO CHECK WHEN SERVICE IS DUE BY DISTANCE

Same as setting Service Hours, but toggle to SET dIS.

TO CLEAR THE SERVICE REMINDER FROM THE DIS-

PLAY

The reminder will remain in the LCD window until the button is

pushed or it is reprogrammed for the next service interval. When

this is done the display will return to the normal menu showing

odometer, trip meter and hour meter.

If the service interval isn’t reprogrammed the reminder will be

displayed each time the speedometer is powered up; again

pushing the button can clear the display.

CONTROL AND PARTS FUNCTIONS

Engine Throttle and Choke

Throttle L ever

Engine speed and vehicle

movement are controlled by

pressing the throttle lever.

The throttle lever (1) is

spring loaded and engine

speed returns to idle when

the lever is released.

This vehicle is equipped with

a Polaris Electronic Throttle

Control (ETC) which is de-

signed to reduce the risk of a

frozen or stuck throttle. In the event the throttle cable should stick

in an open position, the engine will stop and power to the rear

wheels will cease when the operator releases the throttle lever.

Choke

Refer to the engine starting procedure on page 65 for correct

choke (2) and throttle settings during starting.

Do not start or operate an ATV with sticking or improperly op-

erating throttle controls. A stuck or improperly operating

throttle could cause an accident resulting in severe injury or

death.

Always contact your dealer for service repairs whenever

throttle problems a rise.

Failure to check or maintain proper operation of the throttle

system can result in the throttle lever sticking during riding

and cause an accident.

Always check the lever for free movement and return before

starting the engine and occasionally during riding.

CONTROL AND PARTS FUNCTIONS

Front and Rear Brakes

The brake fluid in the master cyl-

inder, which is located on the left

handlebar, should be checked

before each ride. The fluid level

can be seen through the plastic

reservoir (1), and should be

maintained between the indi-

cated max (2) and min (3) marks

on the reservoir. On some mod-

els, there is an indicator window

(4)o n the top of the mastercylin-

der. This “eye” will appear dark

when the fluid level is full. When

fluid needs to be added, the eye

will be clear. NOTE: When

checking the fluid level, the ATV

must be on levelground the the handlebarsstraight. If the fluid lev-

el is low add DOT 3 (PN 2870990) only.

The Electronic Throttle Control (ETC) stops the engine in

the even t of a throttle system malfunction and is provided

for your safety. Do not attempt to modify the ETC syste m

or replace it with any after market throttle mechanisms.

Once a bottle of brake fluid is opened, use what is necessary

and discard the rest. Do not store or use a partial bottle of

brake fluid. Brake fluid is hygroscopic, meaning it rapidly ab-

sorbs moisture from the air. This causes the boiling tempera-

ture of the brake fluid to d rop, which can lead to early brake

fade and the possibility of severe injury.

CONTROL AND PARTS FUNCTIONS

The front and rear brakes are applied by squeezing the left side

brake lever toward the handlebar. The front and rear brakes are

hydraulically activated disctype brakes which are activated by one

lever only.

Always testbrake levertravel and reservoirfluidlevel beforeriding.

When squeezed, the lever should feel firm. Any sponginess would

indicate a possible fluid leak or low master cylinderfluid levelwhich

must be corrected before riding. Contact your dealer for proper

diagnosis and repairs.

Never operate the ATV with a spongy feeling brake lever.

Operating the ATV with a spongy brake lever can result in

loss of braking. Loss of braking could cause an accident.

CONTROL AND PARTS FUNCTIONS

Parking Brake

Setting the Parking Brake - A

1. Squeeze the left hand brake

lever two or three times and

hold it.

2. Rotate the park brake lock (1)

into the notches on the mas-

ter cylinder body. Release

the brake lever.

3. To release the parking brake

lock, squeeze the brake le-

ver. It will return to its re-

leased position.

Always check to be sure that the parking brake has been dis-

engaged before operating the ATV. An accident could result

causing severe injury if the parking brake is left on while the

ATV is operated.

CONTROL AND PARTS FUNCTIONS

Setting the Parking Brake - B

1. Squeeze the left hand brake

lever two or three times and

hold it.

2. Push the park brake lock (2)

into the notches on the mas-

ter cylinder body. Release

the brake lever.

3. To release the parking brake

lock, squeeze the brake le-

ver. It will return to its re-

leased position.

Important Safeguards

D The parking brake may relax when left on for a long period

of time. This could cause an accident.

D Do not leave the vehicle on a hill depending on the park-

ing brake for more than five minutes.

D Always block the downhill side of the wheels if leaving the

ATV on a hill or park the ATV in a side hill position.

Auxiliary Power Outlet

Auxiliary power outlets provide 12V power for operating accesso-

ries such as hand held spot lights.

On select models, an outlet is located on the front headlight pod.

To determine if your vehicle is equipped with auxiliary power outlet,

please check your Owner ’s Manual Supplement.

Accessory outlets are available for all models. Contact your Polar-

is dealer for more information.

CONTROL AND PARTS FUNCTIONS

Auxiliary Brake

Your Polaris ATV has an auxiliary brake provided as a safety fea-

ture. It is located on the inside of the right floor board and is oper-

ated by the right foot. It is intended as a backup to the main brake

system, especially if the main system becomes inoperative.

If the rear wheels slide, reduce brake pedal pressure to brake the

rearwheelswithoutskidding. Aggressivelyapplyingthe rearbrake

when backing down a hill may cause rear tip over.

Brake F lu id L evel

It will be necessary to check the brake fluid level for the auxiliary

brake system. The reservoir is located under the seat or near the

foot brake. The fluid should be kept between the maximum and

minimum marks.

Use caution when applying the auxiliary brake. Do not aggres-

sively apply the auxiliary brake when going forward or the rear

wheels may skid and slide sideways causing loss of control.

Auxiliary

Brake

Pedal

CONTROL AND PARTS FUNCTIONS

Automatic Transmission Gear Selector Op eration

Shift patterns depend on the

type of vehicle you own. Please

check your Owner ’s Manual

Supplement to define your ma-

chine’s shift pattern.

Thetransmission gear selectoris

located on the right side of the

vehicle directly above and for-

ward of the engine recoil starter.

The transmission selector lever

has three or four positions: high

forward; reverse; neutral; and

low forward or forward; reverse;

and neutral. Check your Own-

er ’s Manual Supplement for

specification.

NOT E: To extend belt life, use low forward gear in heavy pulling

situations and in situations where you are operating below 7

miles per hour for extended periods of time.

Always place the transmission in gear with the parking brake

locked whenever the vehicle is left unattended.

Maintaining shift linkage adjustment is important to assure proper

transmission function. Should you experience any shifting prob-

lem see your dealer.

To change gears, stop the vehicle and with the engine idling,

move the lever to the desired gear. Shifting gears with the en-

gine speed above idle or while the vehicle is moving could

cause transmission damage.

CONTROL AND PARTS FUNCTIONS

Manual Shift Operation

The engine can only

be started with the

transmission in neu-

tral.

Turn the key to “on”

and ensure the stop

switch is in the run

position.

The neutral indicator

light should be on. If

it is not, shift the foot

pedal down ( or up

and down, if in Re-

verse) to find neutral.

Refer to the gear shift

pedal illustrated on

this page.

Once the vehicle is in

neutral, start the en-

gine by engaging the

start button.

Brake Start F eatu re

This model also has a

brake start feature

that can be used

when it is difficult to

find neutral. To acti-

vate, pull on the LH

brake lever and push

on the start switch.

Gear Shift Pedal

To shift to a higher gear,

raise the pedal one full

stroke.

To downshift, depress the

pedal one full stroke.

CONTROL AND PARTS FUNCTIONS

Gear Shift Pedal

The gear shift pedal is above the left floorboard. One full stroke

of the pedal shifts the transmission to the next higher or lower gear

in the shifting sequence. The pedal automatically returns to the

horizontal position when released.

The Xpedition has five forward gears (1, 2, 3, 4, and 5). To upshift

to a higher gear, put the toe of your boot under the gear shift pedal

and raise the pedal one full stroke. To downshift, step on the gear

shift pedal and depress the pedal one full stroke.

Shifting Gears

Start the engine and let it warm up, follow this procedure:

1. With the transmission in neutral, hold the brake lever.

2. With the throttle closed, raise the gear shift pedal one full stroke

to shift into first gear.

3. Release the brake leverand increase enginespeed by gradual-

ly opening the throttle.

4. When speed increases, release the throttle and shift to 2nd

gear by raising the gear shift pedal one full stroke.

5. Repeat sequence 4. to progressively upshift to 3rd, 4th and 5th

(top) gear.

6. To downshift, reverse sequence 4. Remember to release the

throttle each time you shift to the next lower gear.

POTENTIAL HAZARD

Shifting gears without releasing the throttle.

WHAT CAN

HAPPEN

Could cause loss of control or cause the ATV to overturn.

HOW TO AVOID THE

HAZARD

Always release the throttle when shifting gears.

WARNING

CONTROL AND PARTS FUNCTIONS

Shifting to Reverse

With the ATV running and in neutral, hold the brake lever and push

the Reverse/Override button on the LH control. Depress the gear

shift pedal one stroke. The reverse indicator light will come on.

Slowly release the brake lever and press throttle control lightly.

See Owner ’s manual page for reverse operation.

Shifting F rom Reverse to Forward

Be sure machine is completely stopped. Hold the brake lever,

raise gear shift pedal one full stroke to engage forward gear.

NOTE: neutral is bypassed when shifting from reverse to 1st gear.

To engage neutral,depress gear shiftpedalone fullstroke fromthe

1st gear position.

To Decelerate

When slowing down or stopping, release the throttle and apply the

brakes smoothly and evenly. As you slow down, shift to a lower

gear. Be certain the engine has sufficiently slowed before engag-

ing a lower gear. Improper use of the brakes or shifting can cause

the tires to lose traction, reducing control and increasing the possi-

bility of an accident.

POTENTIAL HAZARD

Engaging a lower gear when the engine speed is too high.

WHAT CAN

HAPPEN

The wheels could stop rotating. This could cause loss of

control, an accident and injury. It could also cause engine

or drive train damage.

HOW TO AVOID THE

HAZARD

Make certain the engine has sufficiently slowed before

shifting to a lower gear.

WARNING

CONTROL AND PARTS FUNCTIONS

Exclusive Demand 4 Drive System (All Wheel Drive)

Polaris 4 wheel drive ATVs

are equipped with a unique,

Polaris exclusive, Demand 4

Drive (AW D) system which is

activated by a switch (1) on

the right handlebar. When the

switch is “off” the ATV is in 2

wheeldrive at all times. When

the switch is “on” the ATV is in

Demand 4 Drive and the AWD

indicator(2) will light.

When in AWD, the front

wheels will automatically en-

gage anytime the rear wheels

lose traction. When the rear

wheels regain traction, the

front wheels will automatically

disengage.

NOTE: The override switch

also allows activation of De-

mand 4 Drive (AWD) in re-

verse, if Demand 4 Drive

switch is on.

There is no limit to the length of time the vehicle may remain in De-

mand4Drive.

The Demand 4 Drive switch may be turned on or off while the ve-

hicle is moving. If the switch is turned off when the front hubs are

driving they will not release until the rear wheels regain traction.

Do not switch on Demand 4 Drive if the r ear wheels are

spinning. This may cause severe drive shaft and hub

damage.

CONTROL AND PARTS FUNCTIONS

Engage the Demand 4 Drive switch before getting into condi-

tions where front wheel drive m ay be needed. If the rear

wheels are spinning, release the throttle before turning the

Demand 4 Drive switch on.

Disengaging Wheel Hubs

When backing up while in Demand 4 Drive and then going forward,

one or both hubs may remain engaged. If one or both hubs remain

engaged they can be disengaged by stopping, shiftingto and mov-

ing in reverse. Then proceed in forward again.

You can tell if only one front hub is engaged if the handlebars pull

to one side. If both front wheel hubs are engaged, steering effort

increases but remains balanced from left to right, and vehicle

speed is somewhat restricted.

NOTE: If the hubs remain engaged after following these instruc-

tions return the ATV to your dealer for service.

If both hubs were engaged and only one released during op-

eration, loss of control could result. If you experience hub en-

gaging symptoms, use the above disengaging technique be-

fore proceeding. Failure to disengage front hubs as directed

above could result in severe injury or death.

CONTROL AND PARTS FUNCTIONS

Engine Cooling System

Coolant Level

The recovery bottle(1), located on

the left side of the machine, must

be maintained between the mini-

mum and maximum levels indi-

cated on the recovery bottle .

The engine coolant level is con-

trolled or maintained by the recov-

ery syste m. The recovery system

components are the recovery

bottle, radiator filler neck, radiator

pressure cap and connectinghose.

As coolant operating temperature

increases, the expanding (heated)

excess coolant is forced out of the

radiator past the pressure cap and

into the recovery bottle. As engine

coolanttemperature decreases the

contracting (cooled) coolant is

drawn back up from the tank past

the pressure cap and into the radia-

tor.

NOTE: Some coolantleveldrop on new machinesis normal as the

system is purging itself of trapped air. Observe coolant levels and

maintain as recommended by adding coolant to the recovery

bottle. Polaris recommendsthe useof PolarisPremium60/40 anti-

freeze/coolant or a 50/50 mixture of high quality aluminum com-

patible anti-freeze/coolant and distilled water. NOTE: Polaris Pre-

mium 60/40 is already premixed and ready to use. Do not dilute

with water. NOTE: Always follow the manufacturer’s mixing rec-

ommendations for the freeze protection required in your area.

To access the recovery bottle on Gen IV machines (B) it is neces-

sary to remove the left side panel as described on page 115.

CONTROL AND PARTS FUNCTIONS

Engine Cooling System

Radiator Coolant Level Insp ectio n

NOTE: This procedure is

only required if the cooling

system has been drained for

maintenance and/or repair.

However, if the recovery

bottle has run dry, the level in

the radiator should be in-

spected and coolant added if

necessary.

To access the radiator pres-

sure cap:

Gen III (A) - To access the

pressure cap, clean the area

around the oil cap and re-

move the oil cap (2-cycle

models). Remove front cover

by placing your fingers under

the front of the cover and pull-

ing upward. Reinstall oil cap.

Gen IV (B) - Remove the four

screw securing front rack.

Remove front cover by plac-

ing your fingers under the

front of the cover and pulling

upward.

Never remove the pressure cap when the engine is warm or

hot. Escaping steam can cause severe burns. The engine

must be cool before removing the pressure cap.

Pressure Cap

Rack

Front

Cover

CONTROL AND PARTS FUNCTIONS

NOTE: Use of a non-standard pressure cap will not allow the re-

covery system to function properly. Ifthe cap should need replace-

ment contact your dealer for the correct replacement part.

To insure that the coolant maintains its ability to protect the engine,

it is recommended that the system be completely drained every

two years and a fresh mixture of antifreeze and water be added.

Polarisrecommendsthe useof PolarisPremium60/40 anti-freeze/

coolant or a 50/50 mixture of high quality aluminum compatible

anti-freeze/coolant and distilled water. NOTE: Polaris Premium

60/40 is already premixed and ready to use. Do not dilute with wa-

ter. NOTE: Always follow the manufacturer’s mixing recommen-

dations for the freeze protection required in your area.

Using a funnel, slowly add coolant as necessary through the radia-

tor filler neck.

CONTROL AND PARTS FUNCTIONS

Gasoline is highly flammable and explosive under certain

conditions.

D Always exercise extreme caution whenever handling

gasoline.

D Always refuel with the engine stopped and outdoors or

in a well ventilated a rea.

D Do not smoke o r allow open flames or sparks in or near

the area where refueling is performed or where gasoline

is stored.

D Do not over fill the tank. Do not fill the tank neck.

D If you get gasoline on your skin or clothing, immediately

wash it off with soap and water and change clothing.

D Never start the engine or let it run in an enclosed area.

Gasoline powered engine exhaust fumes are poisonous

and can cause loss of consciousness and death in a

short time.

D Shut off fuel valve whenever the ATV is stored or

parked.

The engine exhaust from this prod-

uct contains chemicals known to

cause cancer, birth defects or other

reproductive harm.

CONTROL AND PARTS FUNCTIONS

Engine Fuel and Oil System

Fuel System

The fuel tank filler cap (1)

is located directly behind

the handlebar. Refer to

yourowner’s Manual Sup-

plement for tank capacity.

Use either leaded or un-

leaded gasoline with a

minimum pump octane

number of 87 R+ M/2 oc-

tane.

The fuel valve is located

on the left side of the front

fender and has three posi-

tions:

OFF: For vehicle storage

and whenever transport-

ing.

ON: For normal opera-

tion.

RES: For reserve supply

inthe event of mainsupply

exhaustion.

NOTE: There is about a 7 to 10 mile (11.2 to 16 km) range on re-

serve gas. Always refill the gas tank as soon as possible after hav-

ing used the reserve supply.

Always return valve to “on” position after refueling machine.

Engine Fuel Safety/Fuel/Filter

The Polaris ATV is equipped with a unique in-line fuel filter.

This filter should be replaced by your dealer after every 100 hours

of operation or annually. Do not attempt to clean the fuel filter.

OFF

RES

CONTROL AND PARTS FUNCTIONS

Oil System

On models with a two

cycle engine, the engine

oil injection tank filler cap

(2) is located on the front

of the machine. Refer to

your Owner’s Manual

Supplement to determine

the type of engine your

vehicle has. The tank ca-

pacity is 2 quarts (1.9 l).

On models with a two cycle engine, use only Polarisinjection

oil. Never substitute or mix oil brands. Serious engine dam-

age and voiding of warranty can result.

To avoid serious engine damage always top off the oil level

when refueling.

CONTROL AND PARTS FUNCTIONS

Polaris 2-Cycle Lubricants

Polarishas a family of premiumoils available for use in all ourprod-

ucts and highly recommends their use. The only oils recom-

mended for Polaris 2-cycle ATVs are Polaris Premium 2-cycle oil

or Premium Gold Synthetic 2-cycle oil.

Polaris Premium 2-cycle lubricants are the most advanced for-

mulation of oils specifically designed for today’s 2-cycle engines.

Months of lab and field tests have resulted in a new generation of

2-cycle lubricants. Polaris Premium 2-cycle lubricants provide ad-

ditives for 2-cycle engines lacking in today’s fuel that keep ring

grooves cleaner for less ring sticking and provide improved overall

engine cleanliness. With new generationlubricity technology, they

excel in meeting the lubrication demands of today’s high perfor-

mance2-cycle engines. Theseare optimumoilsrecommendedfor

liquid cooled and air cooled 2-cycle engines. We believe these o ils

are the best available in the market today.

Premium Go ld Synthetic 2-Cycle Oil

Your vehicle has been primed with Premium Gold Synthetic oil.

This lubricant has been specially formulated for low smoke, low

odor and high lubricity. We recommend continued use of this oil

or Premium 2-cycle oil.

Premium 2-Cycle Oil

Polaris also has a TC-W3 premium oil available for use in all of our

2 cycle products. We h ighly recommend its use if premium gold

synthetic is not used. The only oil recommended for this ATV is

Polaris brand oil.

Polaris Premium 2-cycle oils will readily mix with each other, how-

ever do not mix Polaris Premium 2-cycle oils with any other oils as

they may not be compatible and engine damage may occur.

Engine warranty coverage may become void if you use a

brand other than Polaris in your machine.

CONTROL AND PARTS FUNCTIONS

4-Cycle Premium 4 Synthetic Lubricant

Polaris Premium 4 All Season Synthetic engine oil has been spe-

cially formulated for use in Polaris 4-cycle engines. It is a fully syn-

thetic, high performance, multi-viscosity oil designed to provide

the ultimate in lubrication performance and protection.

Premium 4 possesses unsurpassed film strength over the widest

possible temperature range. It resists viscosity and frictional

breakdown in ambient temperatures from -40° F to 120° F. Its ex-

ceptional frictional properties result in more efficient operation,

more power output, lower fuel consumption, and easier starting in

cold temperatures.

Although Polaris Premium 4 is the only oil recommended for use

in this engine, use of any API certified “SH”oilis allowable. Oilmay

need to be changed more frequently if Polaris Premium 4 is not

used. You will also need to follow the manufacturers recommen-

dations for ambient temperature operation.

Use only Polaris Premium 4 All Season synthetic oil (PN

2871271), or API certified “SH” oil. Never substitute or mix oil

brands. Serious engine damage and voiding of warranty can

result.

CONTROL AND PARTS FUNCTIONS

Oil System

Theo il tank is locatedon the left side of the vehicle or on the engine,

depending on the model. To check the oil:

1. Set machine on a level surface.

2. Start the engine and

let it idle for 20-30

seconds.

3. Stop the engine,

remove dipstick and

wipe dry with a clean

cloth.

4. Screw in the dipstick completely, remove it and read the oil

level. NOTE: The dipstick must be screwed in to keep the

angle and depth of stick consistent.

5. Remove dipstick and check to see that the oil level is between

the full and add marks. Add oil as indicated by the level on the

dipstick. Do not overfill.

ADD 8 OZ. NORMAL FULL

Maintain Oil Level In Normal Range

CONTROL AND PARTS FUNCTIONS

Recoil Starter

If the battery is weak and cannot start the engine, use of the recoil

starter located on the right side of the machine will allow vehicle

operation until repairs can be made.

Polaris 4-cycle engines are equipped with automatic decompres-

sors. This makes recoil starting possible by allowing compression

to “leak” at cranking speeds. The decompressor senses when the

engine is spinning fast enough to start and restores compression

for starting.

1. Be certain your vehicle is on a level surface and the parking

brake is set . See page 45.

2. Take the machine out of gear.

3. Grasp the recoil starter tightly and pull slightly until the starter

mechanism engages.

4. Pull the rope abruptly to start the engine.

Do not extend the starter rope so far that it stops This will

cause damage to the recoil assembly.

Make sure the manual start handle is fully seated on the

recoil housing, especially when travelling in wet areas. If it

is not sealed properly, water may enter the recoil housing

and damage components.

CONTROL AND PARTS FUNCTIONS

Drain the recoil housing after operating the ATV in very wet condi-

tions. This should also be done before storing the ATV. The drain

screw is located at the bottom of the recoil housing. Using a

wrench, remove the screw. Reinstall screw once housing has

been drained.

Water will enter the recoil

housing if the starter han-

dle is disengaged from the

rope guide when under

water.

After travelling in wet

areas the recoil housing

and starter should always

be drained completely by

removing the recoil.

Do not open the crankcase

drain unless the engine

has ingested water. On

4-cycle engines, some en-

gine oil will be lost if crank-

case drain is opened.

On the Trail Blazer, the re-

coil handle must be be-

hind the heat shield for it

to seal properly. If it is not

sealedproperly, watermay

enter the recoil housing

and damage components.

A - 250 and 400 Engines

B - 4-Cycle Engines

1. Crankcase Drain 2. Starter Pinion Drain

3. Recoil Drain (above front prop shaft on shaft drive models)

4. Counter Balance Drain (400s)

STARTING THE ENGINE

Procedure for Starting a Cold Engine

NOTE: (A) - top view of the choke lever; (B) - choke button

A B

1. Place the transmission in neutral and reset the parking brake.

2. Turn the fuel tank valve to ON.

3. Sit on the vehicle.

4. Move the choke to the FULL (1) position.

5. Turn the engine stop switch to RUN.

6. Turn the ignition key to ON and press the starter button.

7. On models with a push/pullchoke, the choke is on “FULL”when

the knob is pulled out all the way. The choke is “OFF” when the

knob is pushed in. This is a variable choke and can be adjusted

gradually, depending on how much choke is needed for

starting.

Never run an engine in an enclosed area. Carbon monox-

ide exhaust gas is poisonous and can cause severe injury

or death. Always start engines outdoors.

You must allow your vehicle adequate warm u p time before

operating or engine damage could result.

STARTING THE ENGINE

8. On models with a key ignition, turn the key to start the vehicle.

9. Do not press the throttle while starting the engine.

10. Activate the starter for a maximum of five seconds, releasing

the key or button when the vehicle starts. If engine does not

start, releasethe starterand waitfive seconds;then activatethe

starter for another fiveseconds. Repeat thisprocedure untilen-

gine starts.

After the Engine Starts

1. If the engine slows or stops, use of the choke at its HALF (2)

position will allow proper engine warm up.

2. Vary the engine RPM slightly with the throttle to a id in warm up

until the engine idles smoothly. Then move the choke to OFF

(3).

Cold Weather Operation - 4 Cycle Engines

Polaris offers the following kits for cold weather operation: Oil

Tank Cover, Engine Heater and Oil Tank Heater. These kits re-

duce mois tur e accum ul ati on in the oil tank when the ATV is op-

erated in freezi ng temper atur es .

If you use your ATV a ll year round, it is important to check your

oil level frequently. A rising oil level could indicate the accu-

mulation of water in the bottom of the oil tank. Water in the bot-

tom of the tank can lead to engine damage and must be

drained.

Water accumulation increases as outside temperature de-

creases.

The cold weather kits not only reduce moisture accumulation,

but the heaters provide quicker warm-ups and easier starting.

See your dealer for more information on cold weather operation

and what kit will work best for your driving habits.

VEHICLE BREAK-IN PERIOD

2-Cycle Engines

The break in period for your new Polaris ATV is defined as the time

it takes to use the first tank of gasoline. No single action on your

part is as important as a proper break in period. Careful treatment

of a new engine will result in more efficient performance and longer

life for the engine. Perform the following procedures carefully.

1. Mix 12.8 ounces of injection oil to four gallons (or 16 ounces to

5 gallons) of gasoline in a suitable gas can. Fill the fuel tank as

outlined on page 58.

2. Fill the oil tank with Polaris injection oil.

3. Drive slowly at first. Select an area which is open and will give

you room to familiarize yourself with vehicle operation and han-

dling.

4. Vary the throttle positions.

5. Perform regular checks on fluid levels, controls and all impor-

tant areas on the vehicle as outlined earlier on the daily pre-ride

inspection checklist found on page 12.

Use only Polaris injection oil. Never substitute or mix oil

brands. Serious engine damage and voiding of warranty can

result.

Do not operate at full throttle or high speeds for extended

periods during the first three hours of use. Excessive heat

can build up and cause damage to close fitted engine

parts.

VEHICLE BREAK-IN PERIOD

After the break in period the oil injection system provides the nec-

essary engine lubrication without the need for pre-mixed fuel.

After the first tank of pre-mixed fuel has been used please verify

that the oil level in the oil tank has dropped, indicating that the o il

pump is functioning properly. If the level has not dropped, see your

dealer for oil pump bleeding and repeat the pre-mix procedure.

Fill the oil tank when you refuel your ATV. If you don’t se-

rious engine damage could result.

VEHICLE BREAK-IN PERIOD

4-Cycle Engines

The break in period for your new Polaris ATV is defined as the first

ten hours of operation, or the time it takes to use the first two tanks

full of gasoline. No single action on your part is as important as a

proper break in period. Careful treatment of a new engine will re-

sult in more efficient performance and longer life for the engine.

Perform the following procedures carefully.

1. Fill fuel tank with e ither

unleaded or leaded

fuel which has a mini-

mum pump octane

number of 87= (R+

M)/2.

2. Check oil reservoir level indicated on dipstick. Add oil if neces-

sary.

3. Drive slowly at first. Select an area which is open and will give

you room to familiarize yourself with vehicle operation and han-

dling.

4. Vary the throttle positions. Do not operate at sustained idle.

CAUTION:

5. Perform regular checks on fluid levels, controls and all impor-

tant areas on the vehicle as outlined earlier on the daily pre-ride

inspection checklist found on page 12.

6. Pull only light loads.

7. Break in oil and filter. Change at 20 hours or 500 miles.

Use only Polaris Premium 4 All Season synthetic oil, or API

certified “SH” oil. Never substitute or mix oil brands. Serious

engine damage and voiding of warranty can result.

Do not operate at fullthrottle or high speeds for extended peri-

ods during the first three hours of use. Excessive heat can

build up and cause damage to close fitted engine parts.

ADD 8 OZ. NORMAL FULL

Maintain Oil Level In Normal Range

RIDING GEAR

Safe Riding Gear

Always wear clothing suited to the type of riding you are doing.

ATV riding requires special protective clothing which will make you

feel more comfortable and reduce chances of injury.

1. Helmet

Your helmet is the most impor-

tant piece of protective gear for

safe riding. A helmet can pre-

vent a severe head injury.

Select an approved helmet

which meets or exceeds your

state’s safety standards and

bears either the Department of

Transportation (DOT) label, the

American National Standards

Institute label (ANSI z90.1), or

the Snell Memorial Foundation

label.

2. Eye Protection

Do not depend on sunglasses

for proper eye protection. A pair

of goggles or helmet face shield

offer the best protection for your

eyes. They should be kept clean

and be of shatterproof design

(bearing the markings z2.1 or

VESC 8).

3. Gloves

Off-road style gloves with knuckle pads are the best for comfort

and protection.

4. Boots

The best footwear is a pair of strong over the calf type boots with

heels, such as moto-cross boots.

5. Clothing

To protect your body, long sleeves and pants should always be

worn. Riding pants with kneepads, a jersey and shoulder pads

provide the best protection.

CARRYING LOADS

Your ATV has been designed to carry a certain amount of load.

CARGO WEIGHT should be evenly distributed (1/3 on the front

and 2/3 on the rear) and mounted as low as possible. When oper-

ating over rough or h illy terrain, reduce speed and cargo to main-

tain stable driving conditions. Never exceed the weights specified

in your Owner’s Manual Supplement.

Maximum trailer weight - 850 lbs.(386 kg); maximum vertical hitch

weight - 30 lbs.(14 kg). Select models may tow up to 1225 (556

kg) on level ground only with a maximum vertical hitch weight of

35 lbs. (16 kg). Refer to your Owner’s Manual Supplement to

determine your machine’s capabilities. Know your machine

before your ride.

Maximum grade while trailer towing - 15°. Do not tow any trailer

on a grade steeper than 15°.

If your machine is equipped with a front rack, take care when load-

ing. Improper loading of the front rack can obstruct the headlight

beam, reducing night visibility. Do not obstruct the headlight beam

with cargo.

Use of low forward gear is recommended in heavy pulling s it -

uations to extend belt life.

CARRYING LOADS

2/3 of Load on

Rear Rack

1/3 of Load on

Front Rack

Important Safeguards

To reduce r isk of injury or machine damage when carrying

loads, read and follow the warnings listed below:

D REDUCE SPEED AND ALLOW GREATER DISTANCE

FOR BRAKING WHEN CARRYING CARGO.

D CARGO WEIGHT DISTRIBUTION should be 1/3 on the

front rack and 2/3 on the rear rack. When operating

over rough or hilly terra in, reduce speed and cargo to

maintain stable driving conditions. Carrying loads on

one rack only increases the possibility of vehicle tip

over.

D HEAVY LOADS CAN CAUSE BRAKING AND CON-

TROL PROBLEMS. Use extreme caution when apply-

ing brakes with a loaded vehicle. Avoid terrain or situa-

tions which may requir e backing downhill.

D ALL LOADS MUST BE SECURED BEFORE MOVING

VEHICLE. Unsecured loads can create unstable oper-

ating conditions, which could result in loss of control of

the vehicle.

Correct loading of this vehicle is necessary to maintain prop-

er stability and operating characteristics. Overloading or in-

correct positioning of the load affects the vehicle’s turning,

stopping distance and stability. Failure to follow loading re-

quirements could cause severe injury or death.

CARRYING LOADS

D LOADS MUST BE CARRIED AS LOW ON THE RACKS

AS POSSIBLE. Carrying loads high on the racks raises

the center of gravity of the vehicle and creates a less

stable operating condition. When cargo loads are car-

ried high on the racks, the weight of the loads must be

reduced to maintain stable operating conditions.

D OPERATE ONLY WITH STABLE AND SAFELY AR-

RANGED LOADS. When handling off-centered loads

which cannot be centered, securely fasten load and op-

erate with extra caution. Always attach the tow load to

the hitch point designated for your ATV.

D EXTREME CAUTION MUST BE USED when operating

with loads extending over the rack sides. Stability and

maneuverability may be adversely affected, causing the

machinetooverturn.

D DO NOT BLOCK THE FRONT HEADLIGHT BEAM

when carrying loads on the front rack.

D DO NOT TRAVEL FASTER THAN THE REC-

OMMENDED SPEEDS. 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 corner-

ing, or while ascending or descending a hill.

DAILY PRE-RIDE INSPECTION

Use the following checklist to verify your machine is in properwork-

ing order each time you ride.

Item/Inspection Procedure

1. Tires - check condition and pressures

2. Fuel and oil tanks - fill both tanks to their proper levels

3. All brakes - check operation, adjustment and fluid level (in-

cludes auxiliary brake)

4. Throttle - check for free operation and closing

5. Headlight/Taillight/Brakelight - check operation of all indicator

lights and switches

6. Engine stop switch - check for proper function

7. Wheels - check for tightness of wheel nuts and axle nuts; check

that axle nuts are secured by cotter p ins

8. Drive chain - condition and slack; refer to drive chain adjust-

ment

9. Air cleaner element - check for dirt; clean or replace

10. Steering - check for free operation noting any unusual loose-

ness in any area

11. Loose parts - visually inspect vehicle for any damaged compo-

nents or loose nuts/bolts or fasteners

12. Operators helmet, goggles and clothing

13. Engine coolant - (Liquid Cooled Models Only) check for proper

level at the recovery bottle

You must inspect your ATV each time before riding to ensure

it is in proper working order. If proper inspection is not done,

severe injury or death could result.

RIDING

1. Sit upright with both feet on the footrests and both hands on the

handlebars.

2. After starting the engine and allowing it to warm up, shift the

transmission into gear.

3. Check your surroundings and determine your path of travel.

4. Release the parking brake.

5. Slowly depress the throttle with your right thumb and begin driv-

ing. Vehicle speed is controlled by the amount of throttle open-

ing.

6. Drive slowly, practice maneuvering and using the throttle and

brakes on level surfaces.

RIDING

Making Turns

Practice making turns at slow speeds.

Polaris ATVs are equipped with a solid rear axle which drives both

rear wheels equally at all times. This means that the wheel on the

outside of the turn must travel a greater distance than the inside

wheel when turning and the inside tire must slip traction slightly.

To turn, 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. This technique alters the balance of traction between the

rear wheels allowing the turn to be made smoothly. The same

leaning technique should be used for turning in reverse.

Avoid turning at sharp angles in reverse as tipover and severe

injury may result.

RIDING

Riding On Slippery Surfaces

Whenever riding on slippery surfaces such as wet trails or

loose gravel, or during cold freezing weather, special atten-

tion must be paid to prevent vehicle turnover. Always:

1. Slow down when entering slippery areas.

2. Maintain a high level of alertness, reading the trail and avoiding

quick, sharp turns which can cause skids.

3. Correct a skid by turning the handlebars in the direction of the

skid and shifting your body weight forward.

4. Driving with Demand 4 Drive (All Wheel Drive)engaged can as-

sist in controlling the vehicle in slippery areas.

5. Never apply brakes during a skid. Complete lossof ATV control

can result.

6. Do not operate on excessively slippery surfaces if possible to

avoid.

7. Always reduce speed and use additional caution.

RIDING

Never engage Demand Drive while wheels are spinning as

severe damage to drive train may occur.

Failure to exercise care when operating the ATV on slippery

surfaces can be dangerous.

Loss of tire traction and vehicle control can result in an acci-

dent, including an overturn.

RIDING

Traveling Uphill

25_ Ma x imum

Whenever traveling uphill always travel straight uphill and:

1. Avoid steep hills (25_ maximum).

2. Keep both feet on the footrests.

3. Transfer your weight forward.

4. Proceed at a steady rate of speed and throttle opening.

5. Remain alert and be prepared to take emergency action. This

may include quick dismounting of the ATV.

Exercise extreme caution when traveling in hilly terrain.

Braking and handling are greatly affected. Loss of vehicle

control or overturning of the ATV could occur causing se-

vere injury or death.

RIDING

Sidehilling

Sidehilling your ATV is one of the most dangerous types of

riding and should be avoided if possible. In the event you do

enter into a situation where sidehilling is necessary, always:

1. Slow down.

2. Lean into the hilltransferring your upper bodyweight towardthe

hill while keeping your feet on the footrests.

3. Steer slightly into the hill to maintain vehicle directions.

If vehicle begins to tip, quickly turn the front wheel downhill, if pos-

sible, or dismount on the uphill side immediately!

Improperly crossing hills or turning on hills can be danger-

ous. Loss of vehicle control or overturning of the ATV

could occur causing severe injury or death.

RIDING

Traveling Downhill

Whenever descen d in g a hill, always:

1. Drive directly downhill.

2. Transfer your weight to the rear of the vehicle.

3. Slow down.

4. Apply the brakes slightly to aid in slowing.

Familiarize yourself with the auxiliary rear brake pedal and its use

in the event loss of normal service brakes occurs.

Do not travel at excessive speeds. It is dangerous and can

cause loss of vehicle control and tipping, resulting in severe

injury or death.

RIDING

Turning Around On A Hill

8’

Uphill

If the ATV stalls while climbing a hill, never back it down the

hill! One maneuver which can be used when it is necessary

to turn around while climbing a hill is the K-turn.

1. Stop and lock the parking brake while maintaining body weight

uphill.

2. Leave transmission in forward and shut off engine.

3. Dismount on left or uphill side of ATV.

4. Staying uphill of ATV, turn handlebars full left (while facing front

of ATV).

5. While holding service brake, release parking brake lock and

slowly allow ATV to roll around to your right until ATV is pointing

across the hill or slightly downward.

6. Lock the parking brake and remount ATV from the uphill side,

maintaining body weight uphill.

7. Restart engine with transmission still in forward, release park-

ing brake, and proceed slowly, controlling speed with the ser-

vice brake, until ATV is on reasonably level ground.

Avoid climbing steep hills. Loss of vehicle control or over-

turning of the ATV could occur resulting in severe injury or

death.

RIDING

Crossing Streams

Your Polaris ATV can operate through water up to maximum

recommended depths reaching the footrests. Before fording

streams always:

1. Determine water depths and current.

2. Choose a crossing where both banks have gradual inclines.

3. Proceed slowly, avoiding rocks and obstacles if possible.

4. After crossing, dry the brakes by applying light pressure to the

lever until braking action is normal.

D Avoid operating the ATV through deep or fast flowing water.

If you cannot avoid water which exceeds the recommended

maximum depth, go slowly, balance your weight carefully,

avoid sudden movements, maintain a slow and steady for-

ward motion. Do not make sudden turns or stops and do not

make sudden throttle changes.

NOTE: After running the vehicle in water, it is critical your ma-

chine is serviced as outlined in the maintenance chart beginning

on page 99. The following areas need special attention: engine

oil, transmission oil, front and rear gearcases, and all grease

fittings.

RIDING

If it is impossible to take it to a dealer before starting, follow the

steps outlined below.

D Move the ATV to dry land or at the

very least, to water below the foot

rests.

D Turnthefuelvalveto“OFF”.

D Remove the spark plug.

D Loosen the carburetor drain screw

(1) or remove bowl drain (2).

D For two stroke engines, remove

crankcase drain screw as on page

148.

D Turn the engine over several times

with electric start.

D Dry the spark plug and reinstall or

replace with a new plug.

D Tighten the carburetor drain screw

(1) or reinstall carburetor drain (2).

D Reinstall crankcase drain.

D Turnthefuelvalveto“ON”.

D Attempt to start the engine. If nec-

essary repeat the “drying” procedure.

D Take the machine to your dealer for

service as soon as possible whether

you succeed in starting it or not.

If water has been ingested into the PVT follow the procedure on

page 90 to dry out the PVT.

If your ATV becomes immersed, take it to your dealer before

starting the engine. Major engine damage can result if the

machine is not thoroughly inspected.

RIDING

Trail Obstacles

Keep Alert!

Look ahead and learn to read the trailas you ride. Stay on the right

side of the trail, if possible,and be constantly alertfor hazardssuch

as logs, rocks and low hanging branches.

Not all obstacles are visible. Travel with caution on trails.

severe injury or death can result if your machine comes in

contact with a hidden obstacle.

RIDING

Backing Up

1. Avoid backing up on steep inclines.

2. Always back slowly.

3. When in reverse, apply the brakes lightly for stopping.

4. Avoid turning at sharp angles in reverse.

5. Never open the throttle suddenly while backing.

6. Never activate override button while throttle is open. Loss of

control may result.

NOTE: MostPolaris ATVsare equippedwith a reverse speedlimit-

er. The override button should be used with caution as rearward

vehicle speed is greatly increased. Do not operate at wide open

throttle. Only open the throttle enough to maintain a desired

speed. Manual shift models (Xpedition) do not have a reverse

speed limiter or an override.

Opening the throttle more than required may cause excessive

fuel to build in the exhaust, resulting in engine popping and/or

engine damage.

RIDING

ParkingonanIncline

RIDING

Whenever the Vehicle is Parked

1. Turn the engine off.

2. Place the transmission in gear or in park.

3. Set the parking brake.

4. Avoid parking on an incline. If it is necessary to park on an in-

cline, always block the rear wheels on the down hill side as

shown above.

5. Shut off fuel supply.

PVT SYSTEM OPERATION

PVT System

Low Range Use May Reduce PVT

Operating Temperatures

The basic operation of the Polaris PVT system isdependent on en-

gine speed and vehicle torque requirements. As engine speed in-

creases, the force exerted on the movable drive sheave by the fly-

weights also increases. This, in turn, increases the amount of

“pinch” applied to the drive belt. Similarly, if the engine speed de-

creases, the amount of centrifugal force decreases, reducing the

amount of belt “pinch.”

The PVT system rotates at high speeds, creating large

amounts of force on clutch components. Extensive engi-

neering and testing has been conducted to insure the safety

of this product. However, as the owner you have the follow-

ing responsibilities to make sure this system remains safe:

D Do not modify any component of the PVT system.

Doing so may reduce its strength so that a failure may

occur at high speeds. This system has been precision

balanced. Any modification will cause the system to be

out of balance, creating vibration and additional loads

on components.

D Routine maintenance is the responsibility of the own-

er. Always follow recommended maintenance proce-

dures. See your dealer!

D This PVT system is intended for use on Polaris prod-

ucts only.

D The PVT housing must be securely in place during

operation.

Failure to comply with this warning can result in severe injury

or death.

PVT SYSTEM OPERATION

On Polaris ATVs, the approximate gear ratio difference between

high and low range is 1:2.25. This difference in gearing affects the

operation of the PVT, especially at speeds less than 7 MPH, due

to the system’s dependence on engine speed.

For example, when operating at a ground speed of 3 MPH in low

range, the engine speed would b e around 3000 RPM. This is well

above the engagement speed of 1200 - 1400 RPM. However, in

high range at 3 MPH, the engine would be running at only 1500

RPM. Whenever operating this close to the engagement speed,

the engine may be running at a speed which is too low to provide

adequate “pinch” needed to prevent belt slip. This belt slip is re-

sponsible for creating the excessive heat that destroys belts and

causes outer clutch covers to fail.

By switching to low range while operating at low ground speeds,

the air temperature in the clutch cover is reduced by almost 160

degrees. Reducing the temperature inside the clutch cover ex-

tends the life of the PVT components (belt, cover, etc.).

NOTE; Modelswithouta lowrange shouldavoidheavy pullin g

and extended low-speed operation.

PVT Drying

There may be some instances when water is accidently ingested

into the PVT system. Use the following instructions to dry it out b e-

fore operating:

Shift the transmission into neutral and apply full throttle for no

longer than 10 seconds and repeat as necessary. This will expel

the moisture and air-dry the belt and clutches. Allow the engine

RPM to settle to idle speed and shift the transmission to the lowest

available range and test for belt slippage. If the belt slips, repeat

the process.

Take the vehicle to your dealer for service as soon as possible.

PVT SYSTEM OPERATION

When To Use Low Range vs. High Range

The following lists provide a guideline for when to use low range

rather than high.

Low Range:

S Basic operation at speeds less than 7 MPH

S Heavy pulling

S Riding through rough terrain (swamps, mountains, etc.) at low

ground speeds

High Range:

S Basic operation at speeds greater than 7 MPH

S High ground speeds

BATTERY

Battery

Replenishing the Battery Fluid

A poorly maintained battery will

deteriorate rapidly. Check the bat-

tery fluid leveloften. The fluid level

should be kept between the upper

and lower level marks.

To refill use only distilled water.

Tap water contains minerals which

are harmful to a battery.

Whenever removing the battery, disconnect the negative

(black) cable first. When reinstalling the battery, connect the

negative (black) cable last or an explosive situation could re-

sult causing serious injury or death.

Battery electrolyte is poisonous. It contains sulfuric acid. Se-

rious 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

milkof magnesia, beaten egg, or vegetable oil. Callphysician

immediately.

Eyes: Flush with water for 15 minutes and get prompt medi-

cal attention.

Batteries produce explosive gases. Keep sparks, flame, cig-

arettes, etc. away. Ventilate when charging or using in an en-

closed space. Always shield eyes when working near batter-

ies. KEEP OUT OF REACH OF CHILDREN.

Maintain

between

upper and

lower level

marks

BATTERY

Battery Removal

1. Disconnect hold down straps holding the electricalbox and bat-

tery in position and remove battery cover.

2. Remove the battery vent tube from the battery.

3. Disconnect the black (negative) battery cable first.

4. Disconnect the red (positive) battery cable next.

5. Lift the battery out of the ATV, being carefulnot to tip it sideways

and spill electrolyte.

Battery In stallatio n an d Conn ectio n s

Battery terminals and connections should be kept free of corro-

sion.

If cleaning is necessary, remove the corrosion with a stiff wire

brush. Wash with a solution of one tablespoon baking soda and

one cup water. Rinse well with tap water and dry off with clean

rags. Coat the terminals with dielectric grease or petroleum jelly.

Be careful not to allow cleaning solution or tap water into the bat-

tery.

If electrolyte spills, immediately wash it off with a solution of

one tablespoon baking soda and one cup water to prevent

damage to the ATV.

To avoid the possibility of explosion, always connect battery

cables in the order specified. Red (positive) cable first; black

(negative) cable last. An exploding battery can cause serious

injury or death.

BATTERY

1. Set the battery in its holder.

2. Install the battery vent tube. It must be free from obstructions

and securely installed. If not, battery gases could accumulate

and cause an explosion. The tube should be routed away from

the frame and body to prevent corrosion. Avoid skin contact

with electrolyte, severe burns could result.

3. First connect and tighten the red (positive) cable.

4. Second connect and tighten the black (negative) cable.

5. Reinstall battery cover and attach the hold down strap.

6. Verify that cables are properly routed.

NOTE:

D When your ATV is placed in storage for three months or

more, the battery should be removed, charged to proper level,

and stored in a cool dry place.

D Before reusing, take the battery to your dealer for testing

and recharging.

D Power plug leads may need to be bent down so that the bat-

tery cover may be installed.

D When installing a new battery, make certain it is fully

charged prior to it’s initial use. Using a new battery that has

not been fully charged can damage the battery resulting in a

shorter life of the battery. It can also hinder vehicle perfor-

mance.

NOISE EMISSION CONTROL

SYSTEM REGULATION

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED!

U.S. Federallaw prohibitsthe following acts or the causing thereof:

(1) The removal or rendering inoperative by any person other than

for purposes of maintenance, repair, or replacement of any device

or element of design incorporated into any new vehicle for the pur-

pose of noise control prior to its sale or delivery to the ultimate pur-

chaser or while it is in use or

(2) the use of the vehicle after such device or element of design

has been removed or rendered inoperative by any person.

ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE

ACTS LISTED BELOW INCLUDE BUT ARE NOT LIMITED TO

THE FOLLOWING:

1. Removal or alteration or the puncturing of the muffler or any en-

gine component which conducts removal of engine exhaust

gases.

2. Removalor alteration or the puncturing of any part of the engine

air induction system.

3. Replacement of any vehicle parts with parts not in compliance

with federal regulations.

4. Lack of proper maintenance.

CAUTION: Remember, exhaust system components are very hot

during and after use of ATV.

D Do not touch exhaust system components. Serious burns

can result.

D Be especially careful when traveling through tall grass. The

potential for fire exists.

USFS Approved Spark Arrestor

Most Polaris ATVs have mufflers that were tested and approved

in accordance with the USFS Forest Service Standard 5100-1A.

For specific information on your model, see the Owner ’s Manual

Specification Supplement that came with your machine.

MAINTENANCE

Spark Arrestor

The exhaust pipe must be periodically purged of accumulated car-

bon as follows:

1. Remove the clean out plugs (1) located on the bottom of the

muffler as shown above.

2. Place the transmission in neutral and start the engine. Purge

accumulated carbon from th e system by momentarily revving

the engine several times.

3. If some carbon is expelled, cover the exhaust outlet and rap on

the pipe around the clean out plugs while revving the engine

several more times.

When cleani ng the spark arr es tor, you must follow the safe-

guards listed below to avoid seri ous injury or death.

D Do not perform this operation immediately after the en-

gine has been run because the exhaust system be-

comes very hot.

D Because of the increased fire hazard, make sure that

there are no combustible materials in the area when

purging the spark a rrestor.

D Wear eye protection.

D Do not stand behind or in front of the vehicle while

purging the carbon from the spark arrestor.

D Never run the engine in an enclosed area. The exhaust

contains poisonous carbon monoxide gas.

D Do not go under the machine while it is inclined.

D Keep combustible materials away from exhaust system.

Fire may result.

MAINTENANCE

4. If particles are still sus-

pected to b e in the

muffler, back the ma-

chine onto an incline

so the rear of the ma-

chine is one foot high-

er than the front. Set

the parking brake and

block the wheels.

Make sure the ma-

chine is in neutral and

repeat steps 2 and 3.

Spark Arrestor

(cont.)

5. If particles are stillsus-

pectedtobeinthe

muffler, drive the ma-

chine onto the incline

so the front of the ma-

chine is one foot high-

er than the rear. Set

the parking brake and

block the wheels.

Make sure the ma-

chine is in neutral and

repeat steps 2 and 3.

6. Repeat steps 2 through 5 until no more particles are expelled

when the engine is revved.

7. Stop the engine and allow the arrestor to cool.

8. Reinstall the arrestor

plugs.

MAINTENANCE

Tool Kits

To help you perform routine maintenance, a tool kit is provided in

the storage compartment under the seat. Items included in the kits

are:

2-cycle engines

D flat screwdriver

D spark plug wrench with Phillips head screwdriver

D wrench

D tire pressure gauge

D spanner wrench for adjusting rear shock spring preload (se-

lected models)

4-cycle engines

D screwdriver

D open end wrench (8-10 mm)

D open end wrench (12-14 mm)

D box end wrench

D tire pressure gauge

D spark plug wrench and handle

D spanner wrench for adjusting rear shock spring preload (se-

lected models)

NOTE: Other tools are also necessary to perform maintenance

work. They are called out later in this manual.

MAINTENANCE

Periodic Maintenance Schedule

Careful periodic maintenance will help keep your vehicle in the saf-

est, most reliable condition. Inspection, adjustment and lubrica-

tion intervals o f important components are explained in the follow-

ing chart on the following pages.

Maintenance intervals are based upon average riding conditions

and an average vehicle speed of approximately 10 miles per hour.

Vehiclessubjected to severe use,such as operation inwet ordusty

areas, should be inspected and serviced more frequently. If you

are not familiar with safe service and adjustment procedures, have

a qualified dealer perform these operations.

Inspect, clean, lubricate, adjust or replace parts as necessary.

NOTE: Inspection may reveal the need for replacement parts. Al-

ways use genuine Polaris parts available from your Polaris dealer.

Service and adjustments are critical. If you are not familiar with

safe service and adjustment procedures, have a qualified dealer

perform these operations.

" More often under severe use, such as dirty or wet

conditions to purge water or dirt contamination from grease

fittings and other critical components.

L Emission Control System Service (California - 4-Cycle) NOTE:

Some 4-Cycle models may have an additional California -only

emissions warranty. Please refer to your owner ’s manual supple-

ment to determine if this applies to your vehicle.

Due to the nature of the adjustments marked with a J on the

following chart

, it is recommended that service be performed by

an authorized Polaris dealer.

100

MAINTENANCE

Item Hours

Miles

When Remarks

Brake System Pre-ride Pre-ride Pre-ride inspection item

Auxiliary Brake Pre-ride Pre-ride Pre-ride inspection item

Tires Pre-ride Pre-ride Inspect daily, pre-ride

inspection item

Wheels Pre-ride Pre-ride Pre-ride inspection item

Frame nuts, bolts,

fasteners

Pre-ride Pre-ride Pre-ride inspection item

Injector Oil Level

(2-Cycle)

Daily Daily Check when refueling

AirFilter-Pre-

Cleaner

Daily Daily Inspect-Clean

Coolant/Level In-

spection

Daily Daily Replace engine coolant

every two years

" Air Box Sediment

T ube

Daily Daily Drain deposits whenev-

er visible

Headlamp Inspec-

tion

Daily Daily Check operation daily;

apply Polaris dielectric

grease to connector

when replaced

Tail lamp inspec-

tion

Daily Daily Check operation daily;

apply Polaris dielectric

grease to socket when

replaced

AirFilter-Main

Element

Weekly Weekly Inspect-Replace if nec-

essary

" Transmission Oil

Level

20 hrs Monthly Inspect monthly;

change annually

Battery 20 hrs Monthly Check Terminals/clean/

check fluid level

Engine Counter-

balance

(400 Engines)

20 hrs Monthly Check oil level; change

annually

101

MAINTENANCE

Periodic Maintenance Schedule (Cont.)

" More often under severe use, such as dirty or wet

conditions to purge water or dirt contamination from grease

fittings and other critical components.

L Emission Control System Service (California - 4-Cycle) NOTE:

Some 4-Cycle models may have an additional California -only

emissions warranty. Please refer to your owner ’s manual supple-

ment to determine if this applies to your vehicle.

Item Hours

Miles

When Remarks

Engine breather fil-

ter

(4-cycle)

20 hrs Monthly Inspect--replace annual-

ly and as needed

J Brake pad wear 10 hrs Monthly Inspect periodically

" Front and Rear

Gearcase Oil

(shaft drive)

100 hrs Monthly Check monthly and

change annually

Engine Cylinder

Head and

Cylinder Base Fas-

teners

25 hrs 3

months

Inspect (re-torque re-

quired at first service

only)

" General Lubrica-

tion

50 hrs 3

months

Lubricate all fittings, piv-

ots, cables, etc.

Due to the nature of the adjustments marked with a J on the

following chart

, it is recommended that service be performed by

an authorized Polaris dealer.

102

MAINTENANCE

Item Hours

Miles

When Remarks

Engine Oil - Level/

Change (4-Cycle)

100 hrs

/ 1000

miles

months

Check Level Daily;

Break in Service at 1

month. Change oil

more often in cold

weather use.

Oil Filter(4-Cycle) 100 hrs

/ 1000

miles

months

Replace with oil change

Oil Pump Cable

(2-Cycle)

50 hrs 6

months

Inspect, adjust, lubri-

cate, replace if required

L Engine breather

hose

(4-cycle)

100 hrs 6

months

Inspect

Carburetor Float

Bowl

50 hrs 6

months

Drain bowl periodically

and prior to storage

J Throttle Cable/

ETC Switch

50 hrs 6

months

Inspect-adjust, lubri-

cate, replace if neces-

sary; pre-ride inspection

item

L Choke (Enricher)

Cable

50 hrs 6

months

Inspect-adjust, lubri-

cate, replace if neces-

sary

Coolant strength/

pressure test sys-

tem

100 hrs 6

months

Inspect strength sea-

sonally; pressure test

system annually

" Front hubs/fluid

check (AWD)

50 hrs 6

months

Check monthly

Shift linkage 50 hrs 6

months

Inspect, adjust

J Drive belt 50 hrs 6

months

Inspect, replace if nec-

essary

" Steering 50 hrs 6

months

Inspect daily, lubricate

" Rear Axle 50 hrs 6

months

Inspect bearings, Lube

103

MAINTENANCE

Periodic Maintenance Schedule (Cont.)

" More often under severe use, such as dirty or wet

conditions to purge water or dirt contamination from grease

fittings and other critical components.

L Emission Control System Service (California - 4-Cycle) NOTE:

Some 4-Cycle models may have an additional California -only

emissions warranty. Please refer to your owner ’s manual supple-

ment to determine if this applies to your vehicle.

Item Hours

Miles

When Remarks

" Front Suspension 50 hrs 6

months

Inspect--lubricate, tight-

en fasteners

" Rear Suspension 50 hrs 6

months

Inspect, tighten fasten-

ers

" Drive Chain(s) 50 hrs 6

months

Inspect daily, adjust and

lubricate if needed

L Spark Plug 100 hrs 12

months

Inspect--replace if nec-

essary

Ignition T iming 100 hrs 12

months

Inspect and adjust as

needed

Fuel System 100

hours

months

Check for leaks at tank

cap, lines, fuel valve, fil-

ter, pump and carbure-

tor. Replace lines every

two years.

J Fuel Filter 100 hrs 12

months

Replace annually

Due to the nature of the adjustments marked with a J on the

following chart

, it is recommended that service be performed by

an authorized Polaris dealer.

104

MAINTENANCE

Item Hours

Miles

When Remarks

Radiator 100 hrs 12

months

Inspect/clean external

surface

Cooling System

hoses

100 hrs 12

months

Inspect

Spark arrestor 100 hrs 12

months

Clean out

" Front hubs/fluid

change (AWD)

100 hrs 12

months

J Clutches (drive

and driven)

100 hrs 12

months

Inspect, clean

Engine Mounts 100 hrs 12

months

Inspect

Valve Clearance

(4-Cycle)

100 hrs 12

months

Inspect/Adjust

J Injector Oil Filter

(2-Cycle)

100 hrs 12

months

Replace

J Shift selector box

(H/L/R)

200 hrs 24

months

Change lubricant every

two years

J Brake fluid 200 hrs 24

months

Change every two

years

J Front wheel bear-

ings (2wd)

300 hrs 36

months

Inspect, replace if nec-

essary

L Idle Speed As Re-

quired

As Re-

quired

Adjust

Recoil housing As re-

quired

As re-

quired

Drain moisture out after

riding in water

J Toe adjustment As re-

quired

As re-

quired

Periodic inspection, ad-

just when parts are re-

placed

Headlight Aim As re-

quired

As re-

quired

Adjust if necessary

105

MAINTENANCE

Lubrication Recommendations

Item Lube Rec Method Frequency*

1. Engine Oil

(2-Cycle)

Polaris

Injection

Oil

Fill oil tank. See page 58. As needed,

when refuel-

ing

2.Engine OIl

(4-Cycle)

Polaris

Premium

4 Synthet-

ic 0W40

Add to proper level on dip-

stick. See page 61.

Check level

daily.

3. Brake

Fluid

DOT 3

Only

Maintain level between fill

lines. See page 43.

As required;

change every

two years or

200 hours

4. Transmis-

sion Oil

Polaris

Premium

Synthetic

gear case

lube

See Page 141 Change

annually or at

100 hours

5. Front

Gearcase Oil

GL5

80-90

Weight

Gear

Lube

See Page 146 Change

annually or at

100 hours

6. Front Prop

Shaft U-joints

Grease+ Locate Fittings and

Grease

Every 3

months or 50

hours

7. Front

Propshaft

Yoke

Grease+ Locate fittings and grease

-- 3 pumps maximum

Every 3

months or 50

hours

8. Drive

Chain(s)

O-Ring

chain lube

SAE

80/90

Lubricate as often as re-

quired. Before each ride

in wet conditions

As required

9. Demand 4

Hubs - All

Wheel Drive

ATVs

Premium

Hub Lube

Remove set screw in

hubs. Rotate wheels to 4

O’clock position. If lubri-

cant is not visible add

more. Reinstall set screw.

Annually or

at 100 hrs

106

MAINTENANCE

Lubrication Recommendations

Operating

Range

Full

4. Transmission

(dipstick)

6. Front Prop Shaft

(U-Joint)

Fill plug

5. Front Gear Case

4. Transmission

(plug)

7. Propshaft Yoke

Fill plug

107

MAINTENANCE

Lubrication Recommendations

10. Front

Drive Axle (U

Joint) (AWD

Models)

Grease+ Locate grease fitting and

grease with grease gun.

Every 3

months or

50 hours

11. Ball Joint L

Grease

Locate fitting on back side of

struts and grease with grease

gun.

Every 3

months or

50 hours

12. Front A

Arm Pivot

Shaft

Grease

**∆

Locate fitting on pivot shaft

and grease with grease gun.

Every 3

months or

50 hours

13. Counter

Balance

Housing (400)

SAE

10/30

Check level on dipstick and

add oil as necessary.

Change annually. To change

oil see page 149.

Check

monthly

and

change

annually

14. Steering

Post Bushings

Grease

Locate fittings on steering

post and grease with grease

gun.

Every 3

months or

50 hours

108

MAINTENANCE

Lubrication Recommendations

10. Axle Cardan

Front Drive

(AWD Models)

13. Counterbalance

Dipstick

14. Steering Post

Bushings

11. Ball Joint

12. Front A-Arm

Pivot Shaft

Upper

9. 4 O’clock

position

9. Demand 4 Hubs

(4x4 only)

109

MAINTENANCE

Lubrication Recommendations

15. Rear Axle

Bearing

Grease

Locate fittings and grease Every 3

months or

50 hours

16. Swing

Arm

Bushings

Grease

Locate fittings on swing arm

and grease with grease gun.

Monthly or

at 20

hours

17. Upper

Control Arms

Grease

**∆

Locate fittings and grease Semi-

annually

18. Lower

Control Arms

Grease

**∆

Locate fittings and grease Semi-

annually

19. Rear

Wheel Hub

Bearing Carri-

Grease

**∆

Locate fitting and grease Semi-

annually

20. Rear Anti-

Roll Bar

Grease

Locate fitting and grease Semi-

annually

L More often under severe use, such as wet or dusty

conditions.

**Polaris Premium all Season Grease or grease conforming to

NLGI No. 2, such as Conoco Superlube M or Mobile-

grease Special.

+ Grease every 500 miles, or before long periods of storage or

after pressure washing, or after submerging in water. Always

use Polaris Premium U-Joint Lube for maximum service of these

driveline components (PN 2871515 3 oz.)(PN 2871551 14 oz.).

∆ When suspension action becomes stiff or after washing.

NOTE: Hours are based on 10 mph average.

110

MAINTENANCE

Lubrication Recommendations

16. Swing Arm Bushings

15. Rear Axle Bearing

17. Upper Control

Arm

19. Rear Wheel

Hub Bearing

Carrier

20. Rear Anti-

Roll Bar

18. Lower Control

Arm

INDEPENDENT REAR SUSPENSION

18. Lower Control

Arm

111

MAINTENANCE

Periodic Maintenance Record

Use the following chart to record periodic maintenance work:

Maintenance

Interval

Performed

Servicing

Date

Servicing

Dealer

or Person

Remarks

First 5 Hrs.

25 Hrs.

50 Hrs.

75 Hrs.

100 Hrs.

112

MAINTENANCE

Handlebar Adjustment

Your ATV has handlebars

which can be adjusted for

your personal fit.

1. Locate handlebar bolts.

On models with a head-

light pod, it will be neces-

sary to remove the upper

headlight pod. On other

models remove the han-

dlebar cover.

2. Loosen the four bolts.

3. Adjust handlebar to de-

sired height. Be sure han-

dlebars do not hit gas tank

or any other part of ma-

chine when turned fully to

left or right.

4. Torque handlebar adjuster

block bolts to 10 to 12 ft.

lbs.

NOTE: Tighten bolts so there is an equal gap at the front and rear

of the handlebar block. Improper gap will result in improper fit of

upper pod.

Improper adjustment of the handlebars or incorrect torquing of

the adjuster block tightening bolts can cause limited steering o r

loosening of the handlebars,resulting in loss of controland pos-

sible serious personal injury or death.

113

MAINTENANCE

The following items should be checked occasionally for tightness;

or if they have been loosened for maintenance service.

Wheel Nut Torque Specifications

Bolt Size Specification

Front 3/8″ 20 Ft. Lbs.

Rear 3/8″ 20 Ft. Lbs.

Rear 1/2″ 50 Ft. Lbs.

NOTE: All nuts that have a cotter pin installed must be ser-

viced by an authorized Polaris Dealer.

Front Wheel Hub Tightening

Front wheel bearing tightness and spindle nut retention are critical

component operations. Service work must be performed by your

authorized Polaris dealer.

114

MAINTENANCE

Rear Spring Adjustment

The rear shock absorberspring is adjusted by rotating the adjuster

in the direction required to increase or decrease spring tension.

NOTE: Accessory springs are available through your Polaris

dealer.

Rear Spring

Adjustment

Cam

Rear Spring

Adjustment

115

MAINTENANCE

Side Panel Removal (Gen IV Models)

Side panel removal may be difficult until the locking tabs and re-

ceivers have been snapped and unsnapped a few times.

1. Remove seat. Grasp

rear of side panel

near rear cab. With a

quick and firm

motion, pull the panel

forward and outward

to disengage the two

rear tabs.

2. Place hand on top of

side panel behind the

fuel tank. With a

quick and firm

motion, push down

on the side panel to

disengage the top

rear two tabs. Then

pull up on side panel

to disengage front

upper and lower tab.

3. To reinstall side panel,

align panel tabs with

slots on front cab.

Push panel upward

and forward until tabs

lock. Bend rear of

side panel and insert

the two tabs into the

rear cab.

116

MAINTENANCE

Air Cleaner - 2 Cycle Engine s

Filter Removal and Service Procedure

1. Remove the ATV seat.

2. Unsnap the four clips holding the cover assembly to the air box.

3. Loosen clamp securing the filter and remove the filter.

4. Remove the foam pre-filter from the main filter.

5. Wash pre-filter in soapy water, rinse and let dry.

6. Re-install pre-filter over main filter. Replace main filter if re-

quired.

Filter Installation Procedure

1. Check condition of airbox and replace if necessary.

2. Replace filter over carburetor boot. Make certain filter is fully

seated in the air box.

3. Tighten clamp. Do not overtighten or filter damage may occur.

4. Check cover gasket and replace if required. Be certain the cov-

er is seated properly and snap the four clips on to the cover.

5. Reinstall ATV seat.

117

MAINTENANCE

Cleaning th e Main Filter

NOTE: It is advisable to replace the filter when it is dirty. However,

in an emergency it is permissible to clean the main filter if you ob-

serve the following practices.

1. Never immerse the filter in water since dirt can be transferred

to the clean air side of the filter.

2. If compressed air is used never exceed a pressure of 40 PSI.

Always use a dispersion type nozzle to p revent filter damage

and clean from the inside to the outside.

NOTE: Replace the air filter every 50 hours, and possibly more

often in very d irty conditions.

Air Filter Service - 4 Cycle

1. Remove seat.

2. Release clips and remove

cover.

3. Loosen clamp and re-

move filter

4. Remove fabric type pre-

filter from main filter.

Wash pre-filter in soapy

water and dry it.

5. Reinstall pre-filter over

main filter. Replace main

filter as required.

6. Reinstall filterinto air box and tighten clamp. Do not overtighten

clamp or filter damage may occur.

Main Filter

Pre-Filter

118

MAINTENANCE

Breather Filter and Hose - 4-Cycle Engines With Dry

Sump*

1. Remove the clamps and

pull the filter out of the

hoses. NOTE: It will

not

be necessary to

remove the lower hose

from the engine.

2. Inspect filter for debris.

Blow through gently in

direction of arrow on

filter to check for

clogging. Replace as

needed.

3. Check hoses for cracks, deterioration, abrasion, or leaks.

Replace as needed.

4. Reinstall filter and clamps with arrow pointing toward engine.

* Refer to your owner ’s manual supplement to determine if your

machine has a dry sump.

Operation of your ATV without a breather filter can cause en-

gine damage.

Breather

Filter

119

MAINTENANCE

Steering Inspectio n

The steering assembly of the machine should be checked periodi-

cally for loose nuts and bolts. If loose nuts and bolts are found,

have your dealer tighten them before riding your vehicle.

Camber and Caster

The camber and caster are non-adjustable.

Toe Alignment

You can check the toe

alignment of the vehicle

using the following meth-

od. The recommended

toe alignment is 1/8″ to

1/4″ (.3to.6cm)toeout.

If you discover improper

adjustment have your

dealer correct it.

1. Set the handlebars in

a straight ahead posi-

tion and hold them in

this position.

Do not attempt to adjust the tie rod for toe alignment. Severe

injury or death can result from improper adjustment. Contact

your Polaris dealer. He/she has the training and tools to make

these adjustments.

120

MAINTENANCE

Toe Alignment (cont.)

2. Place stands in front of the machine, perpendicular to the rear

tires.

3. Tie an elastic string around the stands, making sure string just

touches side surface of the rear tires on each side of machine

and goes around the stands in front of the machine.

4. Measure from string to rim at front and rear of front rim. Rear

rim measurement should be 1/16″ -1/8″ (.2 to .3 cm) more than

front rim measurement.

5. If this measurement needs to be adjusted, contact your dealer

for service.

121

MAINTENANCE

Front Brake

The front brakes are hydraulic disc brakes which are activated by

the brake lever being moved toward the handlebar. These b rakes

are self-adjusting and require no adjustment.

The following checks are recommended to keep the brake system

in good operating condition. How often they need checking de-

pends upon the type of driving that has been done.

D Keep fluid level in the master cylinder reservoirs as de-

scribed on page 43. Normal functioning of the diaphragm is

to extend into the reservoir as fluid level drops. If the fluid

level is low and the diaphragm is not extended, a leak is in-

dicated and the diaphragm should be replaced. Always fill

the reservoir as indicated whenever the cover is loosened or

removed to insure proper diaphragm operation. Use Polaris

DOT 3 brake fluid (PN 2870990).

D Check brake system for

fluid leaks.

D Check brake for excessive

travel or spongy feel.

D Check friction pads for

wear, damage and loose-

ness.

D Check security and surface

condition of the disc.

D Pads should be changed when friction material is worn to

3/64″ (.1 cm) (A), or about the thickness of a dime.

Once a bottle of b rake fluid is opened, use what is necessary

and discard the rest. Do not store or use a partial bottle of

brake fluid. Brake fluid is hygroscopic, meaning it rapidly ab-

sorbs moisture from the air. This causes the boiling tempera-

ture of the brake fluid to drop, which can lead to early brake

fade and the possibility of serious injury.

122

MAINTENANCE

Rear and Auxiliary Brake

Rear Brake

The rear brake is a hydraulic disc type brake which is activated by

the same lever which activa tes the front brake system. The rear

brake system is self adjusting and requires no maintenance other

than periodic checks of the pads for wear.

D Pads should be changed when the friction material is worn

to 3/64 ″ (.1 cm) which is about the thickness of a dime.

D Inspect the brake d isc spline and pad wear surface for ex-

cessive wear.

Auxiliary Brake Systems

Your ATV’s auxiliary brake system is intended to be used as a

backup for the main brake system. Should the main system fail,

the rearbrake can be activated by depressing the footpedal on the

inside of the right floorboard. All Polaris ATVs have hydraulic

brake systems. The hydraulic auxiliary brake system will not re-

quire adjustment.

NOTE: Since this is a rear brake only, it will not be as effective as

the a ll wheel system.

123

MAINTENANCE

Oil Pump Adjustment Procedure

400 Engines

1. Before adjusting the oil pump,

check engine idle RPM and

carburetor adjustments which

are found in the owner’s

manual supplement.

2. Loosen throttle cable jam nut

and turn adjuster in or out until

there is 1/16″ -1/8″ (.16 - .32

cm) of throttle lever travel be-

fore throttle slide starts to

open. See Owner ’s Manual

Supplement.

3. Place very slight pressure on the throttle lever until all freeplay

is removed from throttle cable (to the point where the carb slide

is just starting to rise).

4. Lift boot up off adjuster sleeve. Remove the oil pump cover.

Loosen the cable adjuster locknut. Adjust oil pump cable until

marks align (D) when the throttle slide just begins to raise.

5. Tighten the locknut.

6. Recheck adjustment. If correct, slide boot alltheway downover

the upper portion of the bottom nut to ensure good sealing

against water entry. Reinstall oil pump cover and gasket.

Oil Pump Adjustment 400

Boot

Adjuster

Sleeve

Upper Portion

of Bottom Nut

124

MAINTENANCE

Oil Pump Adjustment Procedure - 250 Engines

1. Before adjusting the oil

pump, check engine idle

RPM and carburetor ad-

justments which are found

in the owner ’s manual sup-

plement.

2. Loosen throttle cable jam

nut and turn adjuster in or

out until there is 1/16″ -

1/8″ (.16 - .32 cm) of

throttle lever travel before

throttle slide starts to open.

See Owner’s Manual Sup-

plement.

3. Place very slight pressure

on the throttle lever until all

freeplay is removed from

throttle cable (to the point

where the carb slide is just

starting to rise).

4. Loosen locknut. Turn ad-

juster in or out until all free-

play is removed from oil

pump cable (the point

where the oil pump arm is

just starting to move off of

its stop). The pump stop

keeps the pump arm from

rotating any farther down

than the idle position so n o

visual alignment of marks

is necessary. Tighten the

locknut

Lever

Locknut

Cable Adjuster

Locknut

Lever Arm

125

MAINTENANCE

Oil Pump Bleeding Procedure

1. Fill the oil reservoir with Polaris injector oil.

2. Loosening the bleeder screw is only necessary when the oil

supplyline has been disconnectedfromthepump orthe oilres-

ervoir and supply line have been completely run out of oil. In

these cases, loosen the pump bleed screw one full turn. Allow

oil to flow from the bleed screw for five to ten seconds. Tighten

bleed screw. CAUTION: Never run the engine with the bleed

screw loose. Loss of oil will cause serious engine damage.

3. Start the engine and rotate the oil pump lever to its full open

position. With the engine at idle, hold the lever up for thirty se-

conds to make sure all air is out of the system.

Throttle Cable Adjustment 250 and 400 Engines

Vehicles with 250 and 400 engines do not utilize a cable sleeve

jam nut. You will need to bottom the cable to the carburetor slide-

valve cap. Adjust at throttle cable adjuster near the throttle block.

See page 130 for adjustment procedure.

126

MAINTENANCE

Engine Choke Adjustment 2-Cycle Engines

When the choke is in the full off position, the choke plunger must

be seated on the fuel passageway in the carburetor. If the plunger

is not seated on the passageway, the engine will flood or run too

rich, causing spark plug fouling and very poor engine perfor-

mance.

If there is too much choke cable slack resu lting in excessive free

play, the engine will be hard starting when cold and the half-on

choke position used for intermittent applications will not function.

Choke Adjustment Procedure

1. Flip choke toggle to the full

off position.

2. Loosen adjustment locknut

(A) on carburetor.

3. Turn cable sleeve adjusting

nut (B) clockwise on carbu-

retor until 1/8″ (.3 cm) or

more choke toggle free

play is evident.

4. Turn the cable sleeve ad-

justing nut counterclock-

wise on the carburetor until

the toggle has zero free

play. Then rotate it clock-

wise until 1/8″ to 1/4″ (.3 to

.6 cm)toggle free play isev-

ident.

5. Tighten adjustment lock-

nut.

127

MAINTENANCE

Carburetor/Engine Idle RPM Adjustment

2 Cycle Engines

If the engine idle speed is not satisfactory, and all other conditions

are favorable, the carburetor can be adjusted as follows:

1. Warm up the engine by

running the vehicle

approximately five min-

utes.

2. Place the transmission in

gear with the parking

brake applied.

3. Adjust the carburetor idle

screw in or out until the

desired idle RPM is

reached. Turning the

screw in (clockwise) will

raise RPM. Turning the

screw out (counterclock-

wise) will lower RPM.

The following variations to air screw adjustment for 2-Cycle en-

gines should be noted:

D For improving cold weather start and reducing audible deto-

nation noise, the air screw can be closed from 1/2 to 1 turn

by turning the screw clockwise.

D During hot weather and/or high altitude operation the air

screw can be adjusted for smooth operation by approxi-

mately 2 turns counterclockwise.

Idle

Screw

Air Screw

128

MAINTENANCE

Choke Adjustment Procedure 4-cycle Engines

Toggle Switch

1. Push choke knob to the full

off position.

2. Slide boot off in-line cable

adjuster sleeve. Loosen

adjustment locknut on in-

line cable adjuster.

3. Turn cable sleeve adjusting

nut clockwise on in-line ad-

juster until 1/8″ (.3 cm) or

more choke toggle free

play is evident.

4. Turn the cable sleeve adjusting nut counterclockwise on the in-

line cable adjuster until the toggle has zero free play. Then ro-

tate it clockwise until 1/8″ to 1/4″ (.3 to .6 cm) toggle free play

is evident.

5. Tighten adjustment locknut.

6. Slide boots back over cable adjuster sleeve until they touch at

the middle point of the sleeve.

129

MAINTENANCE

Choke Adjustment Procedure 4-cycle Engines

Push/Pull Choke

1. Locate the boot behind the

choke knob and pull it

back. Loosen the friction

nut 1 turn o r until choke

slides freely. Re-install

boot.

2. Push the choke knob in to

the full off position.

3. Slide boots off in-line cable adjuster and loosen adjustment

locknut.

4. Turn adjuster until the choke knob pushes out over 1/4″.

5. Push on the choke knob lightly while turning the adjuster the

opposite way.

6. Turn the adjuster until the knob contacts the boot.

7. Tighten adjuster locknut.

8. Slide boots back over the cable adjuster until they touch at the

middle of the adjuster.

9. Pull back the choke knob boot and tighten the friction nut until

the choke will maintain a set position. Re-install boot.

Boot

Adjuster

Sleeve

Locknut

Boot

130

MAINTENANCE

Carburetor/Engine Idle RPM Adjustment

4-cycle Eng in es

If the engine idle speed is not

satisfactory, and all other

conditions are favorable, the

carburetor can be adjusted as

follows:

1. Warmup the engine by run-

ning the vehicle approxi-

mately five minutes.

2. Place the transmission in

gear with the parking brake

applied.

3. Adjust the carburetor idle screw in or out until the desired idle

RPM is reached. Turning the screw in (clockwise) will raise

RPM. Turning the screwout (counterclockwise)will lower RPM.

Throttle Cable Free Play Adjustment

Throttle cable free play is adjusted at the handlebar.

1. Slide the bolts off inline cable adjuster sleeve. Loosen adjuster

locknut.

2. Turn adjuster until 1/16″ to 1/8″ freeplay is achieved at thumb

lever. NOTE: While adjusting freeplay, it is important you flip

the throttle lever back and forth.

3. Tighten locknut and slide boots over cable adjuster until they

touch at the mid point of adjuster.

Idle Screw

Boot

Adjuster

Sleeve

Locknut

Boot

131

MAINTENANCE

Spark Plugs

Check your owner ’s manual supplement for recommended spark

plug and gap.

The spark plug and its condition is indicative of engine operation.

The spark plug firing end condition should be read after the engine

is warmed up and the vehicle is driven at higher speeds. Immedi-

ately check the spark plug for correct color.

1. Normal

The insulator tip is gray, tan or light brown. There will be few com-

bustion deposits. The electrodes are not burned or eroded. This

indicates the proper type and heat range for the engine and the

service.

NOTE: The tip should not be white. A white insulator tip indicates

overheating, caused by use of an improper spark plug or incorrect

carburetion adjustments.

2. Wet Fouled

The 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 are excessive oil, use of

non-recommended injection oil, improper use of the choke, or in-

correct carburetion adjustments.

Spark Plug Removal an d Replacement

The spark plug is removed by using the special wrench provided

in the tool pouch. Remove the spark plug cap and then the spark

plug by rotating counterclockwise.

Reverse the procedure for spark plug installation. Torque to 17 ft.

lbs.

Never deviate from the recommended spark plug as engine dam-

age can o ccur.

Never attempt to remove a spark plug while the engine is

warm. The exhaust system or engine could burn you causing

severe injury.

132

MAINTENANCE

Cylinder Head/Cylinder Base Fastener Torque

(2-Cycle Models)

Have your dealer check the ATV cylinder head and cylinder base

fasteners for proper torque at the first service or after 25 hours.

Oil an d Filter Chan ge

The recommended oil change interval is 100 hours, 1000 miles, or

every six months, whichever comes first. Suggested break in oil

change is at 20 hours, 200 miles, or one month, whichever comes

first. Severe use operation requires more frequent service. Se-

vere use includes continuous duty in dusty or wet conditions, and

cold weather riding. NOTE: Severe use cold weather riding is all

riding below 10° F, and riding between 10° F and 30°F when most

trips are slow speed and less than 5 miles. Be sure to change the

oil filter whenever changing oil

Oil may be hot. Do not allow hot oil to come into contact

with skin as severe burns may result.

133

MAINTENANCE

Oil F ilter and Change

(4-Stroke models with an external oil tank)

1. Place vehicle on a level surface.

2. Clean area around drain plug which is found at the bottom of the

oil tank or on the bottom of the engine.

3. Run engine for two to three minutes until warm. Shut engine off.

4. Place a drain pan beneath the plug and remove it.

5. Allow oil to drain completely.

6. Install a new sealing washer on oil drain plug. NOTE: The

sealing surfaces on the drain plug and the oil tank should be

clean and free of burrs, nicks or scratches.

7. Reinstall drain plug and torque to 14-17 ft. lbs. (1.93-2.35 kg/m)

8. Disconnect the lower

oil delivery hose.

Remove the fitting

Clean the fitting

screen. Reinstall

the fitting screen,

torquing to 14-17 ft.

lbs. Reattach oil

line. If banjo fitting

(D) is used, torque

to 14-17 ft. lbs. If

hose clamp (E) is

used, tighten to 25

in. lbs.

9. Place shop towels beneath oil filter. Using an oil filter wrench,

turn filter counterclockwise to remove.

10. Using a clean dry cloth, clean filter sealing surface on

crankcase.

134

MAINTENANCE

Oil Filter and Change (Cont.)

(4-Stroke models with an external oil tank)

11. Lubricate O-Ring on new filter with a film of new engine oil.

Check to make sure the O-Ring is in good condition. Also

make sure the O-ring from the old filter is not still on the engine.

12. Install new filter and tighten by hand 1/2 to 3 /4 turn after gasket

contact.

13. Approximately 1 cup of engine oil will remain in the crankcase.

To drain, remove drain plug found on lower right side of

crankcase. NOTE: The sealing surfaces on the drain plug and

crankcase should be clean and free of burrs, nicks or

scratches.

14. Reinstall drain plug.

15. Remove dipstick and add the amount of oil indicated in your

Owner’s Manual Supplement. Reinstall dipstick. NOTE: If

sump is not drained, add about 1 3/4 quarts initially.

16. Place gear selector in

neutral and set

parking brake.

17. Start engine and let it

idle for one to two

minutes. Stop engine

and inspect for leaks.

18. Re-check oil level on

the dipstick and add

oil as necessary to

bring the level to the

upper mark on the

dipstick.

19. Dispose of used filter and oil properly.

Dipstick

Filter

135

MAINTENANCE

Oil F ilter and Change

Magnum 325 2x4, Magnum 325 4x4, Trail Boss

Oil and Filter Change

1. Place vehicle on a

level surface.

2. Run engine two to

three minutes until

warm. Stop

engine.

3. Clean area around

drain plug.

4. Place a drain pan

beneath engine

crankcase and remove drain plug. CAUTION: Oil may be hot.

Do not allow hot oil to come into contact with skin as serious

burns may result.

5. Allow oil to drain completely.

6. Replace sealing washer on drain plug. NOTE: The sealing

surfaces on drain plug and crankcase should be clean and free

of burrs, nicks or scratches.

7. Reinstall drain plug and torque to 14 ft. lbs. (19 Nm).

8. Place shop towels beneath oil filter. Using an oil filter wrench,

turn filter counterclockwise to remove.

9. Using a clean dry cloth, clean filter sealing surface on

crankcase.

10. Lubricate O-ring on new filterwith a film of engine oil. Checkto

make sure the O-ring is in good condition.

11. Install new filterand turn by hand until filtergasket contactsthe

sealing surface, then turn and additional 1/2 turn.

Crankcase Drain

136

MAINTENANCE

Oil Filter and Change (Cont.)

Magnum 325 2x4, Magnum 325 4x4, Trail Boss

12. Remove dipstick and fill sump with 2 quarts (1.9 l) of Polaris

Premium 4 synthetic oil.

13. Place gear selector in neutral and set parking brake.

14. Start the engine and let it idle for one to two minutes. Stop the

engine and inspect for leaks.

15. Re-check the oil level on the dipstick and add oil as necessary

to bring the level to the upper mark on the dipstick.

16. Dispose of used filter and oil properly.

NOTE: Drain Plug Torque: 14 ft. lbs. (19 Nm); Oil Filter Torque:

Turn by hand until filter gasket contacts the sealing surface, then

turn an additional 1/2 turn.

137

MAINTENANCE

Oil F ilter and Change

Xpedition 325

1. Place vehicle on a

level surface.

2. Run engine two to

three minutes

until warm. Stop

engine.

3. Clean area around

drain plug.

4. Place a drain pan

beneath engine

crankcase and remove drain plug. CAUTION: Oil may be hot.

Do not allow hot oil to come into contact with skin as serious

burns may result.

5. Allow oil to drain completely.

6. Replace sealing washer on drain plug. NOTE: The sealing

surfaces on drain plug and crankcase should be clean and free

of burrs, nicks or scratches.

7. Reinstall drain plug and torque to 14 ft. lbs. (1.9 kgm).

8. Place shop towels beneath oil filter. Using an oil filter wrench,

turn filter counterclockwise to remove.

9. Using a clean dry cloth, clean filter sealing surface on

crankcase.

10. Lubricate O-ring on new filterwith a film of engine oil. Checkto

make sure the O-ring is in good condition.

11. Install new filterand turn by hand until filtergasket contactsthe

sealing surface, then turn an additional 1/2 turn.

12. Remove dipstick and fill sump with 4.5 quarts (4.25L) of Polaris

Premium 4 synthetic oil.

Oil Drain

138

MAINTENANCE

Oil Filter and Change (Cont.)

Xpedition 325

13. Shift machine into neutral and set parking brake.

14. Start the engine and let it idle for one to two minutes. Stop the

engine and inspect for leaks.

15. Re-check the oil level on the dipstick and add oil as necessary

to bring the level to the upper mark on the dipstick.

16. Dispose of used filter and oil properly.

NOTE: Drain Plug Torque: 14 ft. lbs. (19 Nm); Oil Filter Torque:

Turn by hand until filter gasket contacts the sealing surface, then

turn an additional 1/2 turn.

139

MAINTENANCE

Oil F ilter and Change

Xpedition 425

1. Place vehicle on a

level surface.

2. Run engine two to

three minutes until

warm. Stop

engine.

3. Clean area around

drain plug.

4. Place a drain pan

beneath engine

crankcase and remove drain plug. CAUTION: Oil may be hot.

Do not allow hot oil to come into contact with skin as serious

burns may result.

5. Allow oil to drain completely.

6. Replace sealing washer on drain plug. NOTE: The sealing

surfaces on drain plug and crankcase should be clean and free

of burrs, nicks or scratches.

7. Reinstall drain plug and torque to 14 ft. lbs. (1.9 kgm).

8. Place shop towels beneath oil filter. Using an oil filter wrench,

turn filter counterclockwise to remove.

9. Using a clean dry cloth, clean filter sealing surface on

crankcase.

10. Lubricate O-ring on new filterwith a film of engine oil. Checkto

make sure the O-ring is in good condition.

11. Install new filterand turn by hand until filtergasket contactsthe

sealing surface, then turn an additional 1/2 turn.

Oil Drain

140

MAINTENANCE

Oil Filter and Change (Cont.)

Xpedition 425

12. Remove dipstick and fill sump with 5.5 quarts (5.2 l) of Polaris

Premium 4 synthetic oil.

13. Shift machine into neutral and set parking brake.

14. Start the engine and let it idle for one to two minutes. Stop the

engine and inspect for leaks.

15. Re-check the oil level on the dipstick and add oil as necessary

to bring the level to the upper mark on the dipstick.

16. Dispose of used filter and oil properly.

NOTE: Drain Plug Torque: 14 ft. lbs. (19 Nm); Oil Filter Torque:

Turn by hand until filter gasket contacts the sealing surface, then

turn an additional 1/2 turn.

141

MAINTENANCE

Transmission Lubrication - Models with Fill Plug

Scrambler 500 4x4, Xplorer 400, Xplorer 4x4, Magnum

500, Magnum 325 4x4, Magnum 325 2x4

The transmission fill plug is located on the right side of the machine

behind the propshaft shield or footwell.

The transmission lubricant level should be checked every six

monthsor1000 miles(1600 km),whichever comesfirst. Transmis-

sion oil should be changed annually. With the ATV on a level sur-

face, remove fill plug (1) and check the lubricant level. Use the il-

lustration and the chart below to determine the correct fluid level.

The correct transmission lubricant to use is Polaris Premium Syn-

thetic Gearcase Lubricant (PN 2871478).

Model

Oil Level “A” Oil Fill Ounces (ml)

Scrambler 500 4x4 15/8″ 27 (800)

Xplorer 400 15/8″ 27 (800)

Xplorer 4x4 15/8″ 27 (800)

Magnum 500 15/8″ 13.5 (400)

Magnum 325 4x4 15/8″ 13.5 (400)

Magnum 325 2x4 3/4″ 27 (800)

Magnum 4x4 Shown

142

MAINTENANCE

Transmission Oil Changing Procedure

1. Remove the four screws on the footwell and gently pull outward

for access. Remove propshaft shield from the right side of the

vehicle (Scrambler 500 4x4, Xplorer 4x4).

2. Remove fill plug.

3. Remove transmission drainplug locatedon the bottom left hand

side and drain the oil (refer to page for the location of the Mag-

num drain plug). Catch and discard used oil properly.

4. Clean and reinstall the drain plug torque to 14 ft. lbs. (1.93

kg-m).

5.Add the correctamount of PolarisPremium SyntheticGearcase

Lubricant until oil reaches the bottom of the filler hole.

6. Check for leaks.

7. Reinstall propshaft shield or footwell and screws removed in

step 1.

143

MAINTENANCE

Transmission Lubrication - Models with Dipstick

Transmission Dipstick

For most 2x4 models, a transmission dipstick is located on the

right side of the machine. On the Sportsman, the dipstick is lo-

cated near the rear brake disc.

The transmission lubricant level should be checked monthly or

1000 miles (1600 km), whichever comes first. Transmission oil

should be changed annually. With the ATV on a level surface, re-

move fill plug dipstick and check the lubricant level. Lubricant

should be kept at the full mark on the dipstick. The correct trans-

mission lubricant to use is Polaris Premium Synthetic Gearcase

Lubricant (PN 2871478).

144

MAINTENANCE

2x4 Models

To check the level:

1. Remove fill dipstick and

wipe clean.

2. Reinstall dipstick com-

pletely, remove and

check the level. Add the

proper lubricant as re-

quired to bring level into

operating range as

shown.

To change lubricant:

1. Remove skid plate (if

necessary).

2. Place a drain pan beneath the transmission oil drain plug area.

3. Loosen jam nut (A).

4. Turn adjuster bolt (B) in to allow the removal of drain plug (C).

5. Remove the drain plug and wipe the magnetic end clean to

remove accumulated metallic filings.

6. After the oil has drained completely, install a new sealing

washer and install the drain plug. Torque to 14 ft. lbs. (19.3

Nm).

7. Turn adjuster bolt (B) out until it touches the frame, and then an

additional 1/2 turn.

8. Tighten the jam nut securely while holding the adjuster bolt.

9. Add the proper lubricant through the dipstick hole until the oil

level is between the upper and lower limits. Do not overfill.

10. Check for leaks.

11.Reinstallskidplateifremovedinstep1.

145

MAINTENANCE

Sportsman Transmission Oil Changing Procedure

1. Remove fill plug/dipstick.

2. Remove transmission drain plug side

and drain the oil. Catch and discard

used oil properly.

3. Clean and reinstall the drain plug.

4. Add 32 oz. (948 ml) Polaris Premium

Synthetic Gearcase Lubricant (PN

2871478 - 12 o z. bottle) to full mark on

the fill plug/dipstick.

5. Check for leaks.

Full

Operating

Range

146

MAINTENANCE

Front Gearcase Lubrication

The front gearcase fill plug is lo-

cated as shown.

The front gearcase lubricant

level should be checked every

six months or 1000 miles (1600

km), whichever comes first.

Front gearcase oil should be

changed annually.

Type A - With the ATV on a level

surface, remove fill plug and

check the lubricant level. Lubri-

cant should be kept at the bot-

tom of fill plug thread. The cor-

rect gearcase lubricant to use is

GL5 80-90 Weight Gear Lube.

Type B - The lubricant level in

this type of gearcase cannot be

checked. You must periodically

drain it and refill it according to

the following procedure.

Gearcase Oil Chan ging

Procedure

1. Remove fill plug (1).

2. Remove gearcase drain plug

located on the bottom right

hand side and drain the oil.

3. Clean and reinstall the drain plug and tighten securely (14 ft.

lbs/1.93 kgm).

4. Add 4 ounces (120 ml) (Type A) or 5 ounces (150 ml) (Type B)

of GL5 80-90 Weight Gear Lube.

5. Reinstall filler plug.

6. Check for leaks.

147

MAINTENANCE

Rear Gearcase Lubrication

With the ATV on a level surface,

remove fill plug and visually in-

spect the lubricant level through

the fillhole (1). Lubricantshould

be kept even with the center of

the drillpoint (2)approximately1

5/8″ below the top of the fillhole.

NOTE: Do not add lubricant to

the bottom of the fill plug

threads. The correct gearcase

lubricant to use is GL5 80-90

Weight Gear Lube.

Oil Changing Procedure

1. Remove drain plug (3). Catch

and discard used oil properly.

2. Clean and reinstall the drain

plug with a new sealing

washer and tighten securely

(14 ft. lbs./1.93 kgm).

3. Remove fill plug and add 10

ounces (300 ml of GL5 80-90

Weight gear Lube and in-

spect oil level. Oil level

should be kept even with the

center of the drill point

(approximately 1 5/8″ below

the top of the fill hole).

4. Reinstall the fill plug. Tighten

securely (14 ft. lbs/1.93 kgm).

5. Check for leaks

15/8″

148

MAINTENANCE

Counter Balance Lubrication - 400 Engines

1. Counter Balance Drain

2. Crankcase Drain

3. Recoil Drain

4. Starter Pinion Drain

The counter balance oil

should be checked semi-

annually and oil should be

added or changed as nec-

essary. The oil should be

changed annually, espe-

cially before off season

storage. If the machine is

used in wet conditions the

oil should be checked more

frequently. If the oil has a

milky appearance it should

be changed as soon as

possible. Failure to proper-

ly maintain this important

area can result in prema-

ture wear or possible failure

of the counter balance

components. Always use

SAE 10W30 oil.

149

MAINTENANCE

Procedure for Adding Oil

1. Remove seat and locate

dipstick (1).

2. Remove dipstick. Oil level

is shown on dipstick.

3. Add SAE 10W30 oil with a

transmission fluid funnel

until oil is at the proper level

on the dipstick. If over-

filled, excess oil will be ex-

pelled through the vent

hose.

4. Reinstall dipstick.

NOTE: Recommended Oil

Level (2).

Counter Balance Oil

Changing Procedure

1. Remove skid plate.

2. Remove counter balance

drain plug. Catch used oil

and discard of properly.

3. Clean and reinstall drain

plug.

4. Add 10W30 oil to full mark on dipstick. Capacity after draining

is approximately 70-75 cc (2.3 - 2 .5 oz.).

5. Reinstall dipstick and check for leaks.

150

MAINTENANCE

Important Safeguards

Maintain proper tire pressure according to charts below. Improper

tire inflation may affect ATV maneuverability.

Do not use improper tires. The use of non-standard size or type

tires may affect ATV handling.

Make certain the wheel are installed properly. If wheels are im-

properly installed it could affect vehicle handling and tire wear.

Wheel Removal Procedure

1. Stop the engine, place the transmission in gear and lock the

parking brake.

2. Loosen the wheel nuts slightly.

3. Elevate the side of the vehicle by placing a suitable stand under

the footrest frame.

4. Remove the wheel nuts and remove the wheel.

Operating your ATV with worn tires, improperly inflated tires,

non-standard tires or improperly installed tires will affect ve-

hicle handling which could cause an accident resulting inseri-

ous injury or death.

Follow the safeguards listed below to prevent this type of

situation.

151

MAINTENANCE

Wheel Installatio n

1. With the transmission in gear and the parking brake locked,

place the wheel in the correct position on the wheel hub. Be

sure the valve stem is toward the outside and rotation arrows

on the tire point toward forward rotation.

2. Attach the wheel nuts and

finger tighten them.

3. Lower the vehicle to the

ground.

4. Securely tighten the wheel

nuts according to the chart

found on page 113:

Tire Insp ectio n

When replacing a tire always

use original equipment size

and type.

Tire Tread Depth

Always replace tires when

tread depth is worn to 1/8″ (.3

cm) (1) or less. Please refer to

your Owner’s Manual Supple-

ment for tire specifications.

152

MAINTENANCE

Drive Chain Inspection and Adjustment

Polaris ATV drive chains are equipped with O-ring sealed perma-

nently greased pins and rollers. However, it is still necessary to lu-

bricate the outer surfaces of the roller.

Always inspect the drive chain prior to operating the vehicle,

checking for damaged or missing O-rings, rollersand correct slack

adjustment. Maintain the stone guard to rear sprocket clearance

at 1/8″ (.3 cm).

Regularly lubricate the drive chain with SAE 80-90 lube or an ap-

proved O-ring chain spray lube.

Never wash the chain with a high pressurewasherorgasoline.

Damage to the O-rings will result, causing premature wearand

drive chain failure.

153

MAINTENANCE

Rear Drive Chain Slack Adjustment

(Models with Concentric Drive)

Check the amount of chain slack by moving the vehicle slightly for-

ward to gain slack at the top side of the rear chain. At this point

the chain should have 3/16″-3/8″ (.48 cm - .95 cm) deflection (1).

If the chain needs adjustment, use the following procedure.

Never adjust or operate the vehicle with the rear drive chain

too loose or too tight as severe damage to the transmission

and drive components can result.

3/16″-3/8″ (.48 cm - .95 cm) Deflection

154

MAINTENANCE

Adjustment Procedure

1. Loosen chain guide.

2. Loosen two eccentric lock-

ing bolts (2).

3. Loosen caliper mounting

bracket bolts located under

the axle.

4. Insert a pin punch through

the sprocket hub and into

the eccentric axle housing.

5. Roll the ATV forward or back

to adjust chain slack to the

proper tension.

6. Tighten caliper mount bolts

10-12 ft. lbs. (1.4 - 1.7 kg/m)

7. Tighten the eccentric locking

bolts to 30 ft. lbs. (9 kg/m) for

machines without the hitch

and 45 ft. lbs. (13.7 kg/m) for

machines with a hitch.

8. Remove pin punch.

9. Reinstall chain guard.

NOTE: Reposition chain guide

to allow 1/8″ (.3 cm) clearance

between sprocket and guide.

Rear Drive Chain Adjustment

Proper Splice-

link Clip Open-

ing Position

155

MAINTENANCE

Headlight Lamp Replacement

Headlight Lamp Replacement - Scrambler

1. Remove wire harness connector from the back of headlight.

2. Grasp bulb housing, turn counterclockwise and remove bulb.

3. Install bulb into headlight housing and rotate clockwise firmly.

NOTE: Bulb is to be positioned so the harness installs into the

lamp at the bottom.

4. Reinstall connector.

Keep you headlights and taillights clean. Poor lighting while

riding can result in an accident causing severe injury or death.

Do not service while headlight is hot. Serious burns may

result.

Do not touch a halogen lamp with bare fingers. Oil from

your skin leaves a residue, causing a hot spot which will

shorten the life of the lamp.

156

MAINTENANCE

High Beam Headlig ht Adjustment

The headlight beam can be adjusted up and down.

1. Place the vehicle on a level surface with the headlight approxi-

mately 25’ (7.6 m) from a wall.

2. Measure the distance from the floor to the center of the head-

light and make a mark on the wall at the same height.

3. Start the engine and turn the headlight switch to high beam.

4. Observe headlight aim. The most intense part of the headlight

beam should be aimed 2″ (5.1 cm) below the mark placed on

thewallinstep2. NOTE: Rider weight must be included on the

seat.

5. Loosen pivot bolt and adjust beam to desired position.

6. Tighten nut and bolt. Torque to 60 in. lbs.

157

MAINTENANCE

Headlight Lamp Replacement ( Trail Blazer)

1. Remove front cover and unplug the light harness.

2. Remove rubber cap from back of headlight to reveal retention

screw.

3. Remove small phillips head screw, and carefully remove bulb

from housing.

4. Insert new bulb into housing and tighten retention screw, install

rubber cap.

5. Reconnect light harness.

6. Install cover to machine.

7. Properly adjust headlight aim.

Headlight Adjustment

1. Place the vehicle on a

level surface with the

headlight approxi-

mately 25’ (7.6 m)

from a wall.

2. Measure the distance

from the floor to the

center of the headlight

and make a mark on

the wall at the same

height.

3. Start the engine and turn on headlight.

4. Observe headlight aim. The most intense part of the headlight

beam should be aimed 8″ (20.3 cm) below the mark placed on

thewallinstep2. NOTE: Rider weight must be included on the

seat.

5. Adjust beam to desired position by turning adjustment screws

(1) in headlight cover. Turning right screw clockwise moves the

intense spot of light up to the left. Turning the left screw clock-

wise moves intense spot of light up to the right. Turning the bot-

tom screw clockwise adjusts the light upwards.

158

MAINTENANCE

Headlight Lamp Replacement ( Gen II)

1. Remove the seat.

2. Remove the plastic panel

surrounding the upper por-

tion of the gas tank by first re-

moving the gas tank cap.

3. Remove the Phillips head

screws on either side of the

panel at the junction of this

panel, the lower panels, and

the rear of the front fenders.

4. Remove the Phillips head

screws on either side of the

rear of the upper panel which

were revealed by the removal

of the seat.

5. Disengage the tabs at the

front of the upper panel

where they snap into the low-

er panel surrounding the

headlight assembly. Alsodis-

engage the tabs on the upper

panel which engage with the

lower triangular panels on ei-

ther side of the machine. Lift

off the upper panel and set it

aside.

6. Reinstall the gas tank cap.

7. Remove the panel surrounding the headlight by removing the

Phillips head machine screws from either side of this panel.

Also remove the two To rx screws at the rear of this panel.

8. Ease the panel forward and up to allow you to reach the socket

connected to the headlight lamp.

3. & 4.

159

MAINTENANCE

Headlight Replacement (cont.)

9. Carefully unplug the socket from the lamp. Remove the panel

and set it aside.

10. Stand the panel containing the headlight assembly on end to

allow access to the back of the headlight assembly.

11. Remove bolt and disengage the wire bail holding the headlight

lamp in place and move it out of the way.

12. Grasp the base of the lamp and lift it out.

13. Reverse the previous steps to replace the lamp and reas-

semble the panels.

High Beam Headlig ht Adjustment

The headlight beam can be adjusted to any position desired by

turning the four screws at the outer corners of the lamp housing.

1. Place the vehicle on a level surface with the headlightapproxi-

mately 25’ (7.6 m) from a wall.

2. Measure the distance from the floor to the center of the head-

light and make a mark on the wall at the same height.

3. Start the engine and turn the headlight switch to high beam.

4. Observe headlight aim. The most intense part of the headlight

beam should be aimed 2″ (5.1 cm) below the mark placed on

thewallinstep2. NOTE: Rider weight must be included on the

seat.

5. Adjust beam to desired position by turning screwso n the hous-

ing.

160

MAINTENANCE

Headlight Lamp Replacement (Gen IV)

1. Using a small flat blade screwdriver, push in on the lock tab

through the two smallopenings at the front of the headlight pod.

2. Lift the pod lightly while depressing the tabs.

3. Remove the screw in the back of the headlight pod

4. Lift pod cover up. Disconnect speedometer harnesses from

speedometer. Unplug indicator light harness and remove pod

cover.

5. Unplug headlamp from wiring harness.

6. Remove boot and locking collar from back of lamp housing.

7. Grasp base of lamp and lift it out.

8. Reverse previous steps to replace lamp and reassemble pod.

Make sure tab on lamp locates properly in housing.

Snap pins

into tabs

Position

knob in

slot and

secure in

locking

tabs

Slip O-Ring

over pin

Adjustment

Knob Stop

Route indicator

harness over

handlebar

161

MAINTENANCE

High Beam Headlig ht Adjustment (Gen IV)

The headlight beam can be adjusted to any position desired by

turning the adjusting knob located on the bottom right side of the

headlight pod.

1. Place the vehicle on a level surface with the headlightapproxi-

mately 25’ (7.6 m) from a wall.

2. Measure the distance from the floor to the center of the head-

light and make a mark on the wall at the same height.

3. Start the engine and turn the headlight switch to high beam.

4. Observe headlight aim. The most intense part of the headlight

beam should be aimed 2″ (5.1 cm) below the mark placed on

thewallinstep2. NOTE: Rider weight must be included on the

seat.

5. Adjust beam to desired position by turning the adjustment

knob.

162

MAINTENANCE

Headlight Housing Replacement

1. Using a small flat blade screwdriver, push in on the lock tab

through the two smallopenings at the front of the headlight pod.

2. Lift the pod lightly while depressing the tabs.

3. Remove the screw in the back of the headlight pod

4. Remove three Phillips screws at

back of headlight pod.

5. Lift pod cover up. Disconnect

speedometer harnesses from

speedometer. Unplug indicator

light harness and remove pod

cover.

6. Unplug headlamp from wiring

harness.

7. Remove O-Ring from headlight

pivot pins.

8. Pull headlight housing up to re-

lease from locking tabs.

9. Lift adjusting knob up to remove

from locking tabs.

10. Carefully pull assembly up and out of pod.

11. Reverse steps to install new housing and reassemble pod.

12. Adjust headlight aim by turning adjusting knob.

O-Ring

51/8″

(13 cm)

Distance from headlamp parting

line to end of adjustment knob stop

is 5 1/8″ (13 cm).

163

MAINTENANCE

Taillight/Brakelight Lamp Replacement

If the taillight/brakelight does not

work the lamp may need to be re-

placed.

1. From the rear of the taillight re-

move two screws holding lens

cover in place and remove

lens cover.

2. Remove lamp (A) and replace it

with recommended lamp.

3. Test the taillight/brakelight to see

that it’s working.

4. Rei ns tal l the l ens cover (B) re-

movedinstep1.

Indicator Lamp Replacement - Style I

1. Remove the upper headlightpod (Gen 4) or the front cover(Gen

2) to access the back of the indicator panel.

2. Using a small, straight blade screwdriver, turn the base of

the bad bulb 1/4 turn counter clockwise.

3. Use a needle nose plier or similar tool to pull the lamp out

of the indicator panel housing.

4.Insertthe new bulband seatit by turning it1/4 turnclockwise.

5. Reassembly pod or front cover.

Indicator L amp Replacement - Style II

1. Remove mounting panel as re-

quired.

2. Unplug light from harness, de-

press locking tabs (C) and re-

move from pod.

3. Install new light and reassemble

panel.

164

MAINTENANCE

Cleaning You r ATV

Keeping your ATV clean will not only improve its appearance but

it can also extend the life of various components. With a few pre-

cautions, your ATV can be cleaned much like an automobile.

Washing

If a high pressure type carwash systemis used, extreme care must

be taken to avoid water damage to the wheel bearings, transmis-

sion seals, body panels, brakes and warning labels. Many expen-

sive repair bills can result from using high pressure detergent sys-

tems.

NOTE: If a high pressure car wash is used, grease all zerk fittings

immediately after washing. Also run the vehicle to evaporate any

water that might have entered the engine or exhaust system.

The best and safest way to clean your ATV is with a garden hose

and a pail of mild soap and water. Use a professionaltypewashing

mitten, cleaningthe upper body firstand the lowerpartslast. Rinse

with water frequently and dry with a chamois to prevent water

spots. NOTE: If warning labels are damaged, contact your a Po-

laris dealer for free replacement.

Waxing

Your ATV can be waxed with any non-abrasive automotive paste

wax. Avoid the use of harsh cleaners since they can scratch the

body finish.

Certain products, including insect repellants and chemicals,

will damage plastic surfaces. Care must be taken when

using these products near plastic surfaces.

165

MAINTENANCE

Storage Tips

Cleaning - Outside

...Make necessary repairs and then clean the

ATV thoroughly with a mild soap and warm water solution to re-

move all dirt and grime. Don’t use harsh detergents or high pres-

sure washers. Some detergents deteriorate rubber parts- use dish

soap type cleaners only. High pressure washers may force water

past seals. Drain the recoil housing.

Stabilize Fuel - Fill the fuel tank. Add Polaris Carbon Clean Fuel

Treatment or Polaris Fuel Stabilizer. Follow instructio ns on the con-

tainer for rec ommended am ount. Carbon cl ean will also reduce the

possibility of bacterial growth in the fuel system. It’s best to allow

15-20 m inutes of operation for the stabilizer to disperse through the

fuel in the tank and carburetor. T ur n the fuel valv e to “OF F” and drai n

the carbur etor bowl com pletely.

Oil And Filter Change - (4-Strokes) Warm the engine and change

oil and filter.

Air Filter / Air Box - Inspect and clean or replac e the pre-c leaner and

air filt er. Cl ean the air box and dr ain the sediment tube.

Breather Filter(s) - On 4-Strokes, inspect and clean or replacethe

breather filter(s).

Inspect All Fluid Levels - Inspect the following fluid levels and

change if necessary: engine counter balance (2-strokes); front

gear case (shaft drive models); transmission; front hubs (AWD

models); brake fluid (change every two years or as required if fluid

looks dark or contaminated).

Drain Recoil Housing - Remove drain plug from recoil housing

and drain any moisture present.

Do not star t the engine duri ng the storage peri od. This will dis-

turb the protect i ve fil m created by fogging.

166

MAINTENANCE

* Fog The Engine - 2 Strokes - Polaris Fogging Oil (PN 2870791)

follow directions on the can. 4-Strokes

- Remov e the spark plug and

add 2-3 tablespoons of Premi um 4 Syntheti c 0W40 engine oil. To

acces s the plug hol e use a section of clear 1/4″ hose and a sm al l

plasti c squeeze bottle filled with the pre-measured amount of oil.

Note: Do this carefully! If you miss the plug hole, oil will drain from

the spark plug cavity out the hole at the front of the cyl inder head,

and appear to be an oil leak. Instal lthe spark plug and pull the engine

over slowly with the recoil starter. Oil will be forced in and around the

pist on r i ngs and ring lands , c oati ng the c yli nder wi t h a protecti ve fi l m

of fresh oil.

Check and Lubricate Cables / Grease - Inspect all cables and

lubricate with Polaris Cable Lubricant. Follow lubrication guide-

lines in the Maintenance Section of the Service or Owner’s Manual

to completely grease and lubricate the entire vehicle with Polaris

Premium All Season Grease. Apply Polaris O-ring Chain Lube to

the drive chain(s).

Battery Maintenance - Remove the battery and add distilled wa-

ter as required to the properlevel. Do not use tap water which may

contain minerals that reduce battery life. Apply Polaris Di-Electric

Grease to the terminal bolts and terminals. Charge the battery at

1.4 amps or less until specific gravity of each cell is 1.265 or great-

er. Store the battery in a cool, dry, place. Charge can be main-

tained easily by using Polaris Battery Tendert charger (PN

2871076) or by charging about once a month to make up for nor-

mal 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. The only thing you

need to do is check the fluid level once a month.

Engine Anti-Freeze - Test engine coolant strength and change if

necessary. Coolant should be replaced every 2 years.

Storage Area/Covers - Set tire pressure and safely support the

ATV with the tires 1-2″ off the ground. Be sure the storage area is

well ventilated. Cover the machi ne wit h a genuine Polar i s ATV cover.

NOTE: Do not use pl ast i c or coated m ater i al s . They do not allow

enough ventil ati on to prevent condensati on, and may promote corr o-

sion and oxidation.

167

MAINTENANCE

* If you choose not to use Polaris fogging Oil, perform the following

procedure.

1. Support the front end of the machine so the engine is level or

tilted slightly rearward.

2. Remove spark plug(s). Rotate piston to BDC and pour approxi-

mately two ounces of Polaris 2 Cycle Injector oil into the cylin-

der.

3. Turn the engine over several timesto ensure coverage of piston

rings, cylinder walls and crankshaft bearings.

4. Treat the fuel system with Polaris Carbon Clean.

5. If Polaris fuel system additive is not used, fuel tank, fuel lines,

and carburetor should be completely d rained of gasoline. to

eliminate any fuel remaining in the carburetor, run the engine

until it stops.

Transporting

Whenever the ATV is to be transported the following measures

should be taken.

1. Turn off the engine and remove the key. It may be lost if not

removed.

2.Turnthefuelvalvetooff.

3. Be certain the fuel cap, oil cap, and seat are installed correctly.

4. Always tie the frame of the ATV to the transporting unit securely

using suitable straps or rope.

5. Always place the transmission in gear and lock the parking

brake.

168

MAINTENANCE

Carburetor Adjustments

If the vehicle is to be operated at various altitudes and tempera-

tures, certain adjustments can be made to improve its operation

and driveability. Above 6000 feet (1800 m) the engine air/fuel mix-

ture becomes overly rich. An engine loses approximately3% of its

power for each 1000 foot (304.8 m) increase in elevation. Al-

though this power cannot be regained, changes to the carburetor

and drive system can b e made to allow efficient operation. These

changes include:

1. Carburetorre-jetting to compensate for altitude and/ortempera-

ture changes.

2. Transmission convertor modification to adjust for engine horse-

power loss during high altitude operation. Contact your dealer.

3. On 2 cycle models, air screw adjustments can be made to com-

pensate for temperature changes and/or changes in altitude.

4. On 4-cycle models, pilot screw adjustments can be made to

compensate for temperature changes and/or changes in alti-

tude.

NOTE: Contact your dealer for altitude adjustments. They have

the training and special tools required to perform all necessary

modifications for you.

Accessories

There are a wide range of Polaris Accessories available for ATVs.

Contact your Polaris dealerto find out about the accessories avail-

able for your machine.

169

TROUBLESHOOTING

Clutch Drive Belt & Cover Related Issues: Diagnosis

Possible Causes Solutions/What to do

Loading the ATV into a

pickup or tall trailer when

in high range.

Shift transmission to low range dur-

ing loading of the ATV to prevent belt

burning.

Starting out going up a

steep incline.

When starting out on an incline, use

low range, or dismount the ATV after

first applying the park brake and per-

form the “K” turn as described on

page 82 of this manual.

Driving at low RPM or low

ground speed (at approxi-

mately 3--7 MPH).

Drive at higher speed or use Low

Range. The use of Low Range is

highly recommended for cooler PVT

operating temperatures and longer

component life.

Insufficient warm--up of

ATVs exposed to low am-

bient temperatures.

Warm engine at least 5 min., then

with transmission in neutral, advance

throttle to approx. 1/8 throttle in short

bursts, 5 to 7 times. The belt will be-

come more flexible and prevent belt

burning.

Slow and easy clutch en-

gagement.

Fast, effective use of the throttle for

efficient engagement.

Towing/Pushing at low

RPM/low ground speed.

Use Low Range only.

Plowing snow, dirt, etc./

utility use.

Use Low Range only.

Stuck in mud or snow. Shift the transmission to Low Range,

carefully use fast, aggressive throttle

application to engage clutch. WARN-

ING: Excessive throttle may cause

loss of control and vehicle overturn.

170

TROUBLESHOOTING

Possible Causes Solutions/What to do

Climbing over large ob-

jects from a stopped posi-

tion.

Shift the transmission to Low Range,

carefully use fast, brief, aggressive

throttle application to engage clutch.

WARNING: Excessive throttle may

cause loss of control and vehicle

overturn.

Belt slippage from water

or snow ingestion into the

PVT system.

Shift the transmission to neutral. Us-

ing the throttle, vary the engine rpm

from idle to full throttle. Repeat sev-

eral times as required. During this

procedure, the throttle should not be

held at the full position for more than

10 seconds. Clutch seals should be

inspected for damage if repeated

leaking occurs.

Clutch malfunction. For inspection of clutch components,

please contact your Polaris dealer.

Poor engine performance. Fouled plugs, foreign material in gas

tank, fuel lines, or carburetor. Con-

tact you dealer for further service in-

formation.

GENERAL RANGE OPERATION GUIDELINES:

Low Range Heavy pulling, basic operational

speeds less than 7 MPH, riding

through rough terrain (swamps,

mountains, etc.), low ground speeds.

High Range High ground speeds, speeds above

7MPH.

171

TROUBLESHOOTING

Procedures

The following information is provided to help you identify probable

causes for questions you may have about the operation of your

ATV. See your Polaris dealer with any additional questions you

may have.

ENGINE TURNS OVER BUT FAILS TO START

No Fuel Water in Fuel Spark Plug

Fuel Valve Off Drain System

No Spark to

Spark Plug

Contact Your

Dealer

Clogged Fuel

Valve or filter

172

TROUBLESHOOTING

ENGINE STOPS OR LOSES POWER

No Fuel

Contact Your

Dealer

Contact Your

Dealer

Overuse of

Choke

Spark Plug

Fouled

Engine

Overheated

Clean Engine

Exterior

Turn Fuel

Valveto“Res”

Water in Fuel

Air Filter

Clogged

Reverse Speed

Limiter

Malfunction

Electronic

Throttle Control

Malfunction

Fuel Vent

Line Kinked

or Plugged

Clean Radiator

screen and

Radiator Core

(liquid cooled

models)

173

WARRANTY

LIMITED WARRANTY

Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340,

gives a SIX MONTH LIMITED WARRANTY on all components of

the Polaris All Terrain Vehicle (ATV) against defects in material or

workmanship. Polaris also gives a one year limited warranty on

the finaldrive chain for failure due to defects. This warranty covers

the parts and labor charges for repair or replacement of defective

parts which are covered by this warranty. This warranty begins on

the date of purchase. This warranty is transferrable to another

consumer during the warranty period through a Polaris dealer.

There is a charge of $35.00 payable to Polaris Industries Inc.

REGISTRATION

At the time of sale, the Warranty Registration Form must be com-

pleted 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 AN ATV

SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN

ORDER T O HAVE VALID WARRANTY ON THE ATV. No verifica-

tion 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 originalregistration and received the “custom-

er copy”, please contact your dealer immediately. NO WARRAN-

TY COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS

REGISTERED WITH POLARIS.

Initial dealer preparation and set -- up of your ATV is very important

in ensuring trouble --free operation. Purchasing a machine in the

crate or without properdealerset--up will void your warranty cover-

age.

174

WARRANTY

WARRANTY COVERAGE AND EXCLUSIONS:

LIMITATIONS OF WARRANTIES AND REMEDIES

The Polaris limited warranty excludes any failures that are not

caused by a defect in material or workmanship. This warranty

does not cover accidental damage, normal wear and tear, abuse

or improper handling. This warranty also does not cover any ATV

that has been altered structurally, modified, neglected, improperly

maintained, used for racing, or used for purposes other than for

which it was manufactured, or for any damageswhich occurduring

trailertransit or as a result of unauthorized service or the use of un-

authorized parts. In addition, this warranty does not coverphysical

damage to paint or finish, stress cracks, tearing or puncturing of

upholstery material, corrosion, or defects in parts, components o r

the ATV due to fire, explosions or any other cause beyond Polaris’

control.

This warranty does not cover the use of unauthorized lubricants,

chemicals, or fuels that are not compatible with the ATV. The ex-

clusive remedy for breach of this warranty shall be, at Polaris’ ex-

clusive option, repair or replacement of any defective materials, 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 INCIDEN-

TAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DE-

SCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IM-

PLIED

WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR

OTHER TORT OR OTHERWISE. Some states do not permit the

exclusion or limitation of incidental or consequential damages or

implied warranties, so the above limitations or exclusions may not

apply to you if inconsistent with controlling state law.

175

WARRANTY

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 SIX MONTH WARRANTY PERIOD.

POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES

NOT STATED IN THIS WARRANTY. Some states do not allow li-

mitations on how long an implied warranty lasts, so the above li-

mitation may not apply to you if inconsistent with controlling state

law.

HOW TO OBTAIN WARRANTY SERVICE

If your ATV requires warranty service, you must take it to a Polaris

dealer authorized to repair Polaris ATVs. When requesting war-

rantyservice you must present your copy of the WarrantyRegistra-

tion form to the dealer. (THE COST OF TRANSPORTATION TO

AND FROM THE DEALER IS YOUR RESPONSIBILITY). Polaris

suggests that you u se your original selling dealer; however, you

may use any Polaris Servicing Dealer to perform warranty ser-

vice.

Please work with your dealer to resolve any warranty issues.

Should your dealer require any additional assistance they will con-

tact the appropriate person at Polaris.

This warranty gives you specific legal rights, and you may also

have other rights which vary from state to state.

If any of the above terms are void because of state or federal law,

all other warranty terms will remain in effect.

Engine Oil

1. Always use Polaris engine oil.

2. Never substitute or mix oil brands as serious engine damage

and voiding of warranty can result.

INDEX

176

Air Cleaner 116-117...........

Air Filter, Scramblert 500 117..

All Wheel Drive 52...........

Backing Up 86...............

Battery Installation 93.........

Battery Maintenance 92.......

Battery Removal 93..........

Brake, Auxiliary

Mechanical 47, 122.......

Brake, Front 121.............

Brake, Parking 45-46.........

Brake, Rear 122.............

Brakes, Front 43.............

Brakes, Rear 43.............

Break In Period 69...........

Break In Period (4 Cycle) 67-69

Breather Filter, Sportsman 500,

Xplorer 500 118..........

Camber And Caster 119......

Carburetor Adjustment

(4 Cycle) 130............

Carburetor Adjustment

(2 Cycle) 127............

Carburetor Adjustments 168...

Carrying Loads 71-73.........

Chain Adjustment 153........

Choke Adjustment

(4 Cycle) 128-129........

Choke Adjustment

Procedure 126...........

Choke Lever 42..............

Cleaning Your ATV 164.......

Control, Parts Functions 35-64.

Coolant Level 54.............

Coolant Level Inspection 55...

Counter Balance

Lubrication 148...........

Counter Balance Oil Changing

Procedure 149...........

Crossing Streams 83.........

Cylinder Head Torque 132.....

Daily Pre-ride Inspection 12, 74

Disengaging Wheel Hubs 53...

Drive Chain Adjustment 152...

Engine Choke Adjustment 130.

Engine Choke

Adjustment 126..........

Engine Electrical Switches 35..

Engine Idle Rpm

Adjustment 128-130......

Filter Change 132-140........

Fuel Safety 58...............

Fuel System 58..............

Gearcase Oil Changing

Procedure 146...........

Handlebar Adjustment 112....

Headlight Adjustment, 156-161.

Headlight Lamp

Replacement 155-160.....

Indicator Lamp

Replacement 163.........

Indicator Lights 37............

Light Switches 36............

Load Capacity 71-73.........

Lubricant, 2cycle 60..........

Lubrication

Recommendations 105-110

Main Switch 35..............

Battery 92-94................

Maintenance 96-168..........

Maintenance Record 111......

Maintenance Schedule 99-103.

Making Turns 76.............

Noise Control System 95......

Oil Change 132-140..........

Oil Change, Engine

4 Strokes 135............

Oil Filter Change 135.........

Oil Pump Adjustment 123-124.

Oil Pump Bleeding 125.......

Oil System 58, 62............

Operation Warnings 13-33....

ParkingOnAnIncline 87......

Premium 4 Synthetic

Lubricant 61.............

PVT System 89..............

Rear Spring Adjustment 114...

Recoil Starter 63.............

Riding 75- 88................

Riding Gear 70..............

Riding On Slippery Surfaces 77

Safety Warning And

Operation Decals 3-11.....

Side Panel Removal 115......

Sidehilling 80................

Spark Arrestor 96- 97.........

INDEX

177

Spark Plugs 131.............

Starting A Cold Engine 65.....

Starting The Engine 65-66....

Steering Inspection 119.......

Storage T ips 165.............

Taillight/Brakelight Lamp

Replacement 163.........

Throttle Cable Adjustment 125.

Throttle Lever 42.............

T ire Inspection 151...........

Toe Alignment 119-120.......

Tool Kit 98..................

Torque Specifications 113.....

T rail Obstacles 85............

T ransmission Gear Selector

Operation 48.............

T ransmission

Lubrication 141- 143.......

T ransmission Oil Changing

Procedure 142-145.......

T ransporting 167.............

T raveling Downhill 81.........

T raveling Uphill 79...........

T roubleshooting 169-172......

T urning Around On A Hill 82...

Understanding W arnings 1- 2..

Vehicle Identification

Numbers 34.............

W arranty 173-174............

Wheel Installation 150-151....

Wheel Removal 150..........

Part No. 9915754 Rev. 02

PRINTED IN THE U.S.A.

Read and understand all warning labels and

Owner ’s Manual before operation. Severe

injury or death can result from ignoring

warnings or improper use. Never permit a

guest to operate this vehicle unless the

guest has read and understands all warning

labels and the Owner’s Manual.

WARNING

THIS MANUAL SHOULD REMAIN WITH THE

VEHICLE AT THE TIME OF RESALE.

Polaris 2001 ATV Universal

Product's Documents

User Manual

Specifications

Polaris 2001 ATV UNIVERSAL Questions and Answers

Related Products

AO Smith GTP-199 201 Polaris 50-Gallon Power Direct Vent Condensing Liquid Propane Gas Water Heater Efficient Reliable Performance

AO Smith GTP-150 201 Polaris 50-Gallon Power Direct Vent Condensing Liquid Propane Water Heater for Efficient Heating

AO Smith GSP-150 201 Polaris 34-Gallon Power Direct Vent Condensing Liquid Propane Gas Water Heater Efficient Reliable Performance

AO Smith GSP-100 201 Polaris 34-Gallon Power Direct Vent Condensing Liquid Propane Gas Water Heater for Efficiency and Reliability

AO Smith GSP-150 200 Polaris 34-Gallon Power Direct Vent Condensing Natural Gas Water Heater with Efficient Performance

AO Smith GSP-130 Polaris 34-Gallon Power Direct Vent Condensing Natural Gas Water Heater Efficient Reliable Comfort