A card containing important ATV safety information should be attached
to the owner’s manual on the next page. If you cannot locate this card,
or if it has been removed, please call 1-800-342-3764 for assistance.
The engine exhaust from this
product contains chemicals known
to cause cancer, birth defects or
other reproductive harm.
WARNING
1
We’ve created a Web site just for you!
S
Technical tips
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New product introductions
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Event schedules
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Parts and Service Manual information
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Exciting details about The Way Out
Check it out...
www.polarisindustries.com/owner
2
Copyright 2003 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor
discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference
use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or
reuse of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited. Printed in U.S.A.
3
WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our
world-wide family of Polaris owners. We proudly produce an exciting
line of utility and recreational products.
Polaris Recreational and Utility Vehicles
S Snowmobiles
S All-terrain vehicles (ATVs)
S Watercraft
S Victory motorcycles
S RANGER utility vehicles
Polaris Professional Series Workmobiles
S Utility Task Vehiclest (UTVs)
S Personal Task Vehiclest (PTVs)
S All-Surface Loaders (ASLs)
We believe Polaris sets a standard of excellence for all utility and
recreational vehicles manufactured in the world today. Many years of
experience have gone into the engineering, design, and development of
your Polaris vehicle, making it the finest machine we’ve ever
produced.
For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner’s manual. Your
manual contains instructions for minor maintenance, but information
about major repairs is outlined in the Polaris Service Manual and
should be performed only by a Factory Certified Master Service Dealer
(MSD) Technician.
Your Polaris dealer knows your vehicle best and is interested in your
total satisfaction. Be sure to return to your dealership for all of your
service needs during, and after, the warranty period.
We also take great pride in our Parts Apparel and Accessories (PAA)
products, available through our online store at www.purepolaris.com.
Have your accessories and clothing delivered right to your door!
Polaris, Polaris The Way Out, and Workmobiles are registered
trademarks of Polaris Industries Inc.
4
5
TABLE OF CONTENTS
WELCOME 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE IDENTIFICATION NUMBERS 6. . . . . . . .
SAFETY 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FEATURES AND CONTROLS 36. . . . . . . . . . . . . . .
OPERATION 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMISSION CONTROL SYSTEMS 67. . . . . . . . . . . .
MAINTENANCE AND LUBRICATION 68. . . . . . . . .
SPECIFICATIONS 107. . . . . . . . . . . . . . . . . . . . . . . .
POLARIS PRODUCTS 110. . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 111. . . . . . . . . . . . . . . . . . . . .
WARRANTY 115. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDEX 118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
VEHICLE IDENTIFICATION NUMBERS
The vehicle frame vehicle identification number (VIN)(1) and engine
serial number are important for model identification when registering
your vehicle, when obtaining insurance, and when ordering
replacement parts. If your vehicle is stolen, these numbers are essential
to the recovery and identification of your vehicle.
Remove the spare key and store it in a safe place. Your key can be
duplicated only by mating a Polaris key blank with one of your
existing keys. If both keys are lost, the ignition switch must be
replaced. See your Polaris dealer.
NOTE: Record your vehicle’s ID numbers and key number (2) in the
spaces provided.
1
31XX
2
Frame VIN:
Engine Serial Number (right front side of engine crankcase):
Vehicle Model Number:
Key Number:
7
SAFETY
Operator Safety
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age.
Know Your Vehicle
As the operator of the vehicle, you are responsible for your personal
safety, the safety of others, and the protection of our environment.
Read and understand your owner’s manual, which includes valuable
information about all aspects of your vehicle, including safe operating
procedures.
Safety Training
When you purchased your new ATV, your dealer offered a hands-on
safety training course that covers all aspects of vehicle safety. You were
also provided with printed materials that explain safe operating
procedures. You should review this information on a regular basis.
If you purchased a used Polaris ATV from a party other than a Polaris
dealer, you can request this free safety training from any authorized
Polaris dealer.
A Polaris ATV is an off-road vehicle. Familiarize yourself with all laws
and regulations concerning the operation of this vehicle in your area.
We strongly advise you to strictly follow the recommended
maintenance program outlined in your owner’s manual. This
preventive maintenance program is designed to ensure that all critical
components on your vehicle are thoroughly inspected at specific
intervals.
WARNING
Failure to follow the warnings contained in this manual can
result in severe injury or death.
A Polaris ATV is not a toy and can be hazardous to operate.
This vehicle handles differently than other vehicles, such as
motorcycles and cars. A collision or rollover can occur quickly,
even during routine maneuvers like turning, or driving on hills or
over obstacles, if you fail to take proper precautions.
Read and understand your owner’s manual and all warnings
before operating a Polaris ATV.
8
SAFETY
Operator Safety
The following signal words and symbols appear throughout this
manual and on your ATV. Your safety is involved when these words
and symbols are used. Become familiar with their meanings before
reading the manual.
The safety alert symbol, on your ATV or in this manual, alerts you
to the potential for personal injury.
The safety alert warning indicates a potential hazard that may
result in serious injury or death.
The safety alert caution indicates a potential hazard that may
result in minor personal injury or damage to the machine.
CAUTION
NOTE
A note will alert you to important information or instructions.
A caution indicates a situation that may result in damage to
the machine.
CAUTION
WARNING
9
SAFETY
Operator Safety
S Read this manual and all labels carefully, and follow the operating
procedures described.
S Never operate an ATV without proper instruction. Take a training
course. Beginners should receive training from a certified instructor.
Contact an authorized Polaris ATV dealer or call Polaris at
1-800-342-3764 to find out about the training courses nearest you.
S Never allow anyone under 16 years of age to operate this ATV.
S Never permit a guest to operate the ATV unless the guest has read
this manual and all product labels and has completed a certified safe-
ty training course.
S Always avoid operating an ATV on paved surfaces, including side-
walks, driveways, parking lots, and streets.
S Never operate an ATV on a public street, road or highway, including
a dirt or gravel road.
S Never operate an ATV without wearing an approved helmet that fits
properly. Always wear eye protection (goggles or face shield),
gloves, boots, a long-sleeved shirt or jacket, and long pants.
S Never consume alcohol or drugs before or while operating an ATV.
S Never operate at excessive speeds. Travel at speeds appropriate for
the terrain, visibility and operating conditions, and your experience.
S Never attempt wheelies, jumps or other stunts.
S Always inspect your ATV before each use to make sure it’s in safe
operating condition. Always follow the inspection and maintenance
procedures and schedules outlined in your owner’s manual.
S Always keep both hands on the handlebars and both feet on the foot-
rests of the ATV during operation.
S Always travel slowly and use extra caution when operating on unfa-
miliar terrain. Be alert to changing terrain conditions.
S Never operate on excessively rough, slippery, or loose terrain.
S Always follow proper turning procedures as described in this manu-
al. Practice turning at low speeds before attempting to turn at faster
speeds. Do not turn at excessive speeds.
WARNING
Serious injury or death can result if you do not follow these
instructions and procedures, which are outlined in further detail
within your owner’s manual.
10
SAFETY
Operator Safety
S Always have the ATV inspected by an authorized Polaris dealer if
it’s been involved in an accident.
S Never operate on hills too steep for the ATV or for your abilities.
Practice on smaller hills before attempting larger hills.
S Always follow proper procedures for climbing hills. Check the ter-
rain carefully before ascend a hill. Never climb hills with excessive-
ly slippery or loose surfaces. Shift your weight forward. Never open
the throttle suddenly or make sudden gear changes. Never go over
the top of a hill at high speed.
S Always follow proper procedures for going downhill and for braking
on hills. Check the terrain carefully before you start down a hill.
Shift your weight backward. Never go down a hill at high speed.
Avoid going down a hill at an angle, which would cause the vehicle
to lean sharply to one side. Travel straight down the hill when pos-
sible.
S Always follow proper procedures for crossing the side of a hill.
Avoid hills with excessively slippery or loose surfaces. Shift your
weight to the uphill side of the ATV. Never attempt to turn the ATV
around on any hill until you’ve mastered (on level ground) the turn-
ing technique outlined in this manual. Avoid crossing the side of a
steep hill when possible.
S Always use proper procedures if you stall or roll backwards while
climbing a hill. To avoid stalling, maintain a steady speed when
climbing a hill. If you stall or roll backwards, follow the special pro-
cedure for braking described in this manual. Always dismount on the
uphill side, or to either side if the ATV is pointed straight uphill.
Turn the ATV around and remount following the procedure de-
scribed in this manual.
S Always check for obstacles before operating in a new area. Never
attempt to operate over large obstacles, such as rocks or fallen trees.
Always follow proper procedures when operating over obstacles as
described in this manual.
S Always be careful of skidding or sliding. On slippery surfaces like
ice, travel slowly and use extra caution to reduce the chance of skid-
ding or sliding out of control.
S Avoid operating the ATV through deep or fast-flowing water. If it’s
unavoidable, travel slowly, balance your weight carefully, avoid sud-
den movements, and maintain a slow and steady forward motion. Do
not make sudden turns or stops, and do not make sudden throttle
changes.
11
SAFETY
Operator Safety
S Wet brakes may have reduced stopping ability. Test your brakes after
leaving water. If necessary, apply them lightly several times to allow
friction to dry out the pads.
S Always check for obstacles or people behind the ATV before operat-
ing in reverse. When it’s safe to proceed in reverse, move slowly and
avoid turning at sharp angles.
S Always use the size and type of tires specified for your ATV, and
always maintain proper tire pressure.
S Never modify an ATV through improper installation or use of acces-
sories.
S Never exceed the stated load capacity for your ATV. Cargo must be
properly distributed and securely attached. Reduce speed and follow
the instructions in this manual for carrying cargo or towing. Allow a
greater distance for braking.
S Always remove the ignition key when the vehicle is not in use to
prevent unauthorized use or accidental starting.
FOR MORE INFORMATION ABOUT ATV SAFETY, call the Con-
sumer Product Safety Commission at 1-800-638-2772, or call
Polaris at 1-800-342-3764.
Equipment Modifications
We are concerned for the safety of our customers and for the general
public. Therefore, we strongly recommend that consumers do not
install on a Polaris ATV any equipment that may increase the speed or
power of the vehicle, or make any other modifications to the vehicle
for these purposes. Any modifications to the original equipment of the
vehicle create a substantial safety hazard and increase the risk of bodily
injury.
The warranty on your Polaris ATV is terminated if any equipment has
been added to the vehicle, or if any modifications have been made to
the vehicle, that increase its speed or power.
NOTE: The addition of certain accessories, including (but not limited
to) mowers, blades, tires, sprayers, or large racks, may change the
handling characteristics of the vehicle. Use only Polaris-approved
accessories, and familiarize yourself with their function and effect on
the vehicle.
12
SAFETY
Operator Safety
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 different
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. Operators should
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
Severe injury and/or death could occur if a child under the
minimum age recommendation operates an ATV.
Even though a child may be within the recommended age group
for operating some ATVs, he/she may not have the skills,
abilities, or judgment needed to operate an ATV safely and could
be susceptible to accident or injury.
HOW TO AVOID THE HAZARD
No one under the age of 16 should operate a Polaris ATV.
WARNING
WARNING
13
SAFETY
Operator Safety
POTENTIAL HAZARD
Carrying a passenger on an ATV.
WHAT CAN HAPPEN
Carrying a passenger greatly reduces the operator’s ability to
balance and control the ATV, which could cause an accident
and injury to the operator and/or passenger.
HOW TO AVOID THE HAZARD
Never carry a passenger. The purpose of the long seat is to
allow the operator to shift position as needed during operation.
It is not intended for carrying passengers.
WARNING
14
SAFETY
Operator Safety
POTENTIAL HAZARD
Operating an ATV on paved surfaces, including sidewalks,
paths, parking lots, and driveways.
WHAT CAN HAPPEN
ATV tires are designed for off-road use. Operating on paved
surfaces may seriously affect the handling and control of the
ATV and could result in loss of control, accident, and/or injury.
HOW TO AVOID THE HAZARD
Avoid operating the ATV on pavement. If it’s unavoidable,
travel slowly and avoid sudden turns or stops.
WARNING
15
SAFETY
Operator Safety
POTENTIAL HAZARD
Operating this ATV on public streets, roads or highways.
WHAT CAN HAPPEN
The ATV could collide with another vehicle.
HOW TO AVOID THE HAZARD
Never operate the ATV on any public street, road or highway,
including dirt and gravel roads. In many states it’s illegal to
operate ATVs on public streets, roads and highways.
WARNING
16
SAFETY
Operator Safety
POTENTIAL HAZARD
Operating this ATV without wearing an approved helmet, eye
protection and protective clothing.
WHAT CAN HAPPEN
Operating an ATV without an approved helmet increases the
risk of a severe head injury or death in the event of an
accident.
Operating without eye protection could result in an accident
and could increase the chance of a severe injury in the event
of an accident.
HOW TO AVOID THE HAZARD
Always wear an approved helmet that fits properly.
Always wear eye protection (goggles or face shield), gloves,
boots, long-sleeved shirt or jacket, and long pants.
WARNING
17
SAFETY
Operator Safety
POTENTIAL HAZARD
Operating the ATV after consuming alcohol or drugs.
WHAT CAN HAPPEN
Consumption of alcohol and/or drugs could seriously affect
operator judgment. Reaction time may be slower and operator
balance and perception could be affected.
Consuming alcohol and/or drugs before or while operating an
ATV could result in an accident causing severe injury or death.
HOW TO AVOID THE HAZARD
Never consume alcohol or drugs before or while operating an
ATV.
POTENTIAL HAZARD
Operating the ATV at excessive speeds.
WHAT CAN HAPPEN
Excessive speed increases the operator’s chance of losing
control of the ATV, which can result in an accident.
HOW TO AVOID THE HAZARD
Always operate the ATV at a speed that’s proper for the terrain,
visibility and operating conditions, and your experience.
WARNING
WARNING
18
SAFETY
Operator Safety
POTENTIAL HAZARD
Attempting wheelies, jumps and other stunts.
WHAT CAN HAPPEN
Attempting stunts increases the chance of an accident, including
an overturn.
HOW TO AVOID THE HAZARD
Never attempt wheelies, jumps, or other stunts. Avoid exhibition
driving.
WARNING
19
SAFETY
Operator Safety
POTENTIAL HAZARD
Failure to inspect the ATV before operating.
Failure to properly maintain the ATV.
WHAT CAN HAPPEN
Poor maintenance increases the possibility of an accident or
equipment damage.
HOW TO AVOID THE HAZARD
Always inspect your ATV before each use to make sure it’s in
safe operating condition.
Always follow the inspection and maintenance procedures and
schedules described in the owner’s manual.
POTENTIAL HAZARD
Removing hands from the handlebars or feet from the
footrests during operation.
WHAT CAN HAPPEN
Removing even one hand or foot can reduce ability to
control the vehicle or could cause loss of balance and
ejection from the ATV.
If the operator’s foot is not firmly planted on the footrest, it
could come into contact with the rear wheels and lead to
accident or injury.
HOW TO AVOID THE HAZARD
Always keep both hands on the handlebars and both feet
on the footrests of the ATV during operation.
WARNING
WARNING
20
SAFETY
Operator Safety
POTENTIAL HAZARD
Failure to use extra caution when operating the ATV on unfamiliar
terrain.
WHAT CAN HAPPEN
Unfamiliar terrain may contain hidden rocks, bumps, or holes that
could cause loss of control or overturn.
HOW TO AVOID THE HAZARD
Travel slowly and use extra caution when operating on unfamiliar
terrain. Always be alert to changing terrain conditions.
WARNING
21
SAFETY
Operator Safety
POTENTIAL HAZARD
Failure to use extra caution when operating on excessively
rough, slippery or loose terrain.
WHAT CAN HAPPEN
Operating on excessively rough, slippery or loose terrain could
cause loss of traction or loss of control, which could result in an
accident or overturn.
HOW TO AVOID THE HAZARD
Do not operate on excessively rough, slippery or loose terrain
until you’ve learned and practiced the skills necessary to
control the ATV on such terrain.
Always use extra caution on rough, slippery or loose terrain.
WARNING
22
SAFETY
Operator Safety
POTENTIAL HAZARD
Turning improperly.
WHAT CAN HAPPEN
Improper turns could cause loss of control and lead to a collision
or overturn.
HOW TO AVOID THE HAZARD
Always follow proper procedures for turning as described in the
owner’s manual.
Practice turning at slow speeds before attempting to turn at
faster speeds.
Never turn at excessive speed.
POTENTIAL HAZARD
Operating on excessively steep hills.
WHAT CAN HAPPEN
The vehicle may overturn.
HOW TO AVOID THE HAZARD
Never operate on hills too steep for the ATV or for your
abilities. Never operate the ATV on hills steeper than 25_.
Practice on smaller hills before attempting large hills.
WARNING
WARNING
23
SAFETY
Operator Safety
POTENTIAL HAZARD
Climbing hills improperly.
WHAT CAN HAPPEN
Improper hill climbing could cause loss of control or overturn.
HOW TO AVOID THE HAZARD
Always follow proper procedures for climbing hills as described
in the owner’s manual.
Always check the terrain carefully before ascending any hill.
Never operate the ATV on hills steeper than 25_.
Never climb hills with excessively slippery or loose surfaces.
Shift your weight forward.
Never open the throttle suddenly while traveling uphill. The ATV
could flip over backwards.
Never go over the top of any hill at high speed. An obstacle, a
sharp drop, or another vehicle or person could be on the other
side of the hill.
WARNING
24
SAFETY
Operator Safety
POTENTIAL HAZARD
Traveling downhill improperly.
WHAT CAN HAPPEN
Improperly descending a hill could cause loss of control or
overturn.
HOW TO AVOID THE HAZARD
Always follow proper procedures for traveling down hills as
described in the owner’s manual. NOTE: A special technique
is required when braking while traveling downhill. See page
58.
Always check the terrain carefully before you descending a hill.
Shift your weight backward.
Never travel down a hill at high speed.
Avoid traveling down a hill at an angle, which would cause the
vehicle to lean sharply to one side. Travel straight down the
hill when possible.
WARNING
25
SAFETY
Operator Safety
POTENTIAL HAZARD
Improperly crossing hills and turning on hills.
WHAT CAN HAPPEN
Improperly crossing or turning as hills could cause loss of control
or overturn.
HOW TO AVOID THE HAZARD
Never attempt to turn the ATV around on any hill until you’ve
mastered the turning technique (on level ground) as described in
the owner’s manual. See page 59. Use extra caution when
turning on any hill.
Avoid crossing the side of a steep hill.
When crossing the side of a hill:
Always follow proper procedures as described in the owner’s
manual.
Avoid hills with excessively slippery or loose surfaces.
Shift your weight to the uphill side of the ATV.
WARNING
26
SAFETY
Operator Safety
POTENTIAL HAZARD
Stalling, rolling backwards or
improperly dismounting while
climbing a hill.
WHAT CAN HAPPEN
The vehicle could overturn.
HOW TO AVOID THE
HAZARD
Maintain steady speed when
climbing a hill.
If all forward speed is lost:
Keep your weight uphill.
Apply the single lever brake gradually.
When fully stopped, apply the auxiliary rear brake as well, then
lock the parking brake.
If the ATV begins rolling backwards:
Keep weight uphill.
Never apply engine power.
Never apply the auxiliary rear brake while rolling backwards.
Apply the single-lever brake gradually.
When fully stopped, apply the auxiliary rear brake as well, and
then lock the parking brake.
Dismount on uphill side, or to either side if ATV is pointed
straight uphill.
Turn the ATV around and remount, following the procedure
described in the owner’s manual. See page 59.
WARNING
27
SAFETY
Operator Safety
POTENTIAL HAZARD
Improperly operating over obstacles.
WHAT CAN HAPPEN
Operating over obstacles could cause loss of control or overturn.
HOW TO AVOID THE HAZARD
Before operating in a new area, check for obstacles.
Avoid operating over large obstacles such as rocks and fallen
trees when possible. If unavoidable, use extreme caution and
always follow proper procedures as outlined in the owner’s
manual.
POTENTIAL HAZARD
Skidding or sliding.
WHAT CAN HAPPEN
Skidding or sliding can cause loss of control.
If the tires regain traction unexpectedly, the ATV could overturn.
HOW TO AVOID THE HAZARD
On slippery surfaces such as ice, travel slowly and use extra
caution to reduce the chance of skidding or sliding out of control.
WARNING
WARNING
28
SAFETY
Operator Safety
POTENTIAL HAZARD
Operating the ATV through deep or fast-flowing water.
WHAT CAN HAPPEN
Tires may float, causing loss of traction and loss of control,
which could lead to an accident or overturn.
HOW TO AVOID THE HAZARD
Avoid operating the ATV through deep or fast-flowing water.
If it’s unavoidable to enter water that exceeds the
recommended maximum depth (see page 60), travel slowly,
balance your weight carefully, avoid sudden movements, and
maintain a slow and steady forward motion. Do not make
sudden turns or stops, and do not make sudden throttle
changes.
Wet brakes may have reduced stopping ability. Always test
the 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
The ATV could collide with an obstacle or person, resulting in
severe injury.
HOW TO AVOID THE HAZARD
Before shifting into reverse gear, always check for obstacles or
people behind the ATV. When it’s safe to proceed, back
slowly.
WARNING
WARNING
29
SAFETY
Operator Safety
POTENTIAL HAZARD
Operating this ATV with improper tires, or with improper or uneven
tire pressure.
WHAT CAN HAPPEN
Use of improper tires, or operation of the ATV with improper or
uneven tire pressure, could cause loss of control or accident.
HOW TO AVOID THE HAZARD
Always use the size and type of tires specified for the ATV.
Always maintain proper tire pressure specified for the ATV.
POTENTIAL HAZARD
Operating the ATV with improper modifications.
WHAT CAN HAPPEN
Improper installation of accessories or modification of the ATV
may cause changes in handling which could lead to an
accident.
HOW TO AVOID THE HAZARD
Never modify the ATV through improper installation or use of
accessories. All parts and accessories added to the vehicle
must be genuine Polaris Industries Inc. or equivalent
components designed for use on this ATV and should be
installed and used according to approved instructions. See
your authorized Polaris ATV dealer for more information.
WARNING
WARNING
30
SAFETY
Operator Safety
POTENTIAL HAZARD
Overloading the ATV or carrying/towing cargo improperly.
WHAT CAN HAPPEN
Overloading and towing can cause changes in vehicle handling,
which could lead to loss of control or an accident.
HOW TO AVOID THE HAZARD
Never exceed the stated load capacity for this ATV.
Cargo should be properly distributed and securely attached.
Reduce speed when carrying cargo or pulling a trailer. Allow a
greater distance for braking.
Always follow the instructions in the owner’s manual for carrying
cargo or pulling a trailer. See page 64.
POTENTIAL HAZARD
Operating on frozen bodies of water.
WHAT CAN HAPPEN
Severe injury or death can result if the ATV and/or the operator
fall through the ice.
HOW TO AVOID THE HAZARD
Never operate the ATV on a frozen body of water. If you’re
confident that the ice is thick enough and sound enough to
support the machine and its operator, as well as the force
created by a moving vehicle, exercise extreme caution.
WARNING
WARNING
31
SAFETY
Operator Safety
After any overturn or accident, have a qualified service dealer
inspect the entire vehicle for possible damage, including (but not
limited to) brakes, throttle and steering systems.
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 overturn and loss of control, which could result in severe
injury or death.
CAUTION
Always keep combustible materials away from the exhaust
system. Exposure to the hot components could result in a fire.
WARNING
WARNING
Leaving the keys in the ignition can lead to unauthorized use of
the vehicle resulting in serious injury or death. Always remove
the ignition key when the vehicle is not in use.
WARNING
32
SAFETY
Safety Decals and Locations
Warning decals have been placed on the ATV for your protection. Read
and follow the instructions of the decals and other warnings on the
ATV carefully. If any of the decals shown in this manual differ from
the decals on your ATV, always read and follow the instructions of the
decals on the ATV.
If any decal becomes illegible or comes off, contact your Polaris dealer
to purchase a replacement. Replacement safety decals are provided by
Polaris at no charge. The part number is printed on the decal.
D
Never operate this vehicle on HILLS steeper than 25 degrees
To prevent flipover on hilly terrain, when going up or down, use throttle
and brakes gradually.
D
REVERSE operation can be dangerous, even at low speeds. Steering be-
comes difficult. To prevent flipover, avoid sudden braking or sharp turns.
D
Use OVERRIDE for reverse speed limiter with caution. To prevent loss
of control, never activate override button with open throttle.
D
PARKING BRAKE may relax when used for more than 5 minutes. When
parking on grades, leave shift in forward.
WARNING
7079085
25°
.
S Moving parts hazard under belt-clutch guard. To
prevent serious injury, do not operate vehicle
with guard removed.
S 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
WARNING
7077920
WARNING
33
SAFETY
Safety Decals and Locations
WARNING
Improper ATV use can result in SEVERE INJURY or DEATH
ALWAYS USE
AN APPROVED
HELMET AND
PROTECTIVE
GEAR
NEVER USE
ON PUBLIC
ROADS
NEVER CARRY
PASSENGERS
NEVER USE
WITH DRUGS
OR ALCOHOL
NEVER operate:
ALWAYS:
34
SAFETY
Safety Decals and Locations
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.
WARNING
7078253
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 models
without a hitch).
To 40 Ft. Lbs. (For models with
a hitch).
7078572
MANUFACTURED
BY: POLARIS IND. INC.
DATE:
VIN:
THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT
INTENDED FOR USE ON PUBLIC ROADS.
7171492
CE VÉHICULE EST UN VÉHICULE TOUT TERRAIN QUI N EST
PAS DESTINÉ À ÊTRE UTILISÉ SUR LES CHEMINS PUBLICS.
Canadian Certification Decal
Reverse Speed is
limited.
Reverse override is
controlled by the
override switch.
See your Owner’s
Manual.
OVERRIDE
SWITCH
7079906
Under Seat
35
SAFETY
Safe Riding Gear
Always wear clothing suited to the type of riding. ATV riding requires
special protective clothing for comfort and to reduce the chance of
injury.
1. Helmet
Your helmet is the most important piece
of protective gear for safe riding. A
helmet can prevent a severe head injury.
Select an approved helmet that 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 a
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 boots with heels, like
moto-cross boots.
5. Clothing
Always wear long sleeves and long pants to protect arms and legs.
Riding pants with kneepads and a jersey with shoulder pads provide
the best protection.
1
2
3
4
5
36
FEATURES AND CONTROLS
Electrical Switches
Activating the override switch while the throttle is open can
cause loss of control, resulting in severe injury or death. Do
not activate the override switch while the throttle is open.
WARNING
Override Switch (1) (Reverse Speed Limiter) -
This vehicle is equipped with a reverse speed
limiter system. To gain additional power while
backing, depress the override switch.
Main Switch (2) - To start the engine, slide the
stop switch to the center RUN position and turn the
main key switch clockwise past the ON position. Release the key when
the engine starts. NOTE: Turning off the main switch will shut off all
electrical power to the vehicle, including the lights.
Engine Stop Switch (3) - 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 an emergency. To
stop the engine, slide the stop switch either right or left to the OFF
position. NOTE: Turning off the engine stop switch will shut off all
electrical power to the vehicle, including the lights.
1
2
3
RUN
OFFOFF
3
Leaving the keys in the ignition can lead to unauthorized use of
the vehicle resulting in serious injury or death. Always remove
the ignition key when the vehicle is not in use.
WARNING
37
FEATURES AND CONTROLS
Throttle Lever
Engine speed and vehicle
movement are controlled by
pressing the throttle lever. The
throttle lever (1) is spring loaded.
Engine speed returns to idle when
the lever is released.
This ATV is equipped with Polaris
Electronic Throttle Control (ETC),
which is designed to reduce the risk of a frozen or stuck throttle. If the
throttle cable should stick in an open position when the operator
releases the throttle lever, the engine will stop, and power to the rear
wheels will cease.
The Electronic Throttle Control (ETC) stops the engine in the
event of a throttle system malfunction and is provided for your
safety. Do not attempt to modify the ETC system or replace it
with any after market throttle mechanisms.
WARNING
Do not start or operate an ATV with sticking or improperly
operating throttle controls, which could cause an accident and
lead to severe injury or death.
Always contact your dealer for service repairs if throttle
problems arise.
Failure to check or maintain proper operation of the throttle
system can result in an accident if the throttle lever sticks
during operation.
Always check the lever for free movement and return before
starting the engine. Also check occasionally during operation.
WARNING
1
38
FEATURES AND CONTROLS
Light Switches
The light switch is located on the
left handlebar (1). It’s used to turn
the lights on and off.
NOTE: The lights won’t work
unless the key is in the ON position
and the shut-off switch is in the
RUN position.
Indicator Lights
With the engine running, verify the function of all indicator lights each
time the ATV is used.
NOTE: The taillight is on whenever the main switch (key) is on.
Turn the key off to prevent battery drain.
1. Transmission Neutral Indicator
2. Transmission Reverse Indicator
3. Oil Warning (indicates a low oil level.
Operating the ATV on streets or roads, especially in darkness,
could result in an accident and serious injury or death.
Your ATV is not equipped with highway-approved lights. It’s
designed for and must be used for off-road use only. Use
caution and drive at reduced speeds in conditions of reduced
visibility such as fog, rain and darkness.
WARNING
1
1
3
2
39
FEATURES AND CONTROLS
Brakes
Check the brake fluid level in the master
cylinder before each use of the ATV.
The master cylinder (1) is located on
the left handlebar.
1. Position the ATV on level ground
with the handlebars straight.
2. View the fluid level through the
indicator window (2) on the top of the master cylinder. This “eye”
will appear dark when the fluid level is full. When fluid needs to
be added, the eye will be clear.
NOTE: Under normal operation, the diaphragm extends into the
reservoir as fluid level drops. If the fluid level is low and the
diaphragm is not extended, a leak is likely and the diaphragm should
be replaced. Always fill the reservoir as needed whenever the cover is
loosened or removed to ensure proper diaphragm operation. We
recommend the use of Polaris DOT 3 brake fluid. Do not overfill.
3. If the fluid level is low, add DOT 3 brake fluid only. See page 110
for the part numbers of Polaris products.
1
2
An over-full master cylinder may cause brake drag or brake
lock-up, which could result in serious injury or death. Maintain
brake fluid at the recommended level. Do not overfill.
WARNING
After opening a bottle of brake fluid, always discard any unused
portion. Never store or use a partial bottle. Brake fluid is
hygroscopic, meaning it rapidly absorbs moisture from the air.
The moisture causes the boiling temperature of the brake fluid
to drop, which can lead to early brake fade and the possibility of
accident or severe injury.
WARNING
40
FEATURES AND CONTROLS
Brake Lever
The front and rear brakes are applied by
squeezing the brake lever (1) toward the
handlebar. The front and rear brakes are
hydraulically activated disc type brakes
that are activated by only one lever.
Always test brake lever travel and master
cylinder fluid level before riding. When
squeezed, the lever should feel firm. Any sponginess would indicate a
possible fluid leak or low master cylinder fluid level, which must be
corrected before riding. Contact your dealer for proper diagnosis and
repairs.
1
Operating the ATV with a spongy brake lever can result in loss
of braking, which could cause an accident. Never operate the
ATV with a spongy-feeling brake lever.
WARNING
41
FEATURES AND CONTROLS
Parking Brake
Setting the Parking Brake
1. Squeeze and release the brake
lever (1) two or three times, then
squeeze and hold.
2. Push the park brake lock (2)
forward to engage the brake.
Release the brake lever.
3. To release the parking brake lock,
squeeze and release the brake
lever. It will return to its unlocked
position.
Important Safeguards
S The parking brake may relax if left on for a long period of time. Al-
ways block the wheels to prevent rolling.
S Always block the wheels on the downhill side of the ATV if leaving
it parked on a hill. Another option is to park the ATV in a sidehill
position.
S Never depend on the parking brake alone if the ATV is parked on a
hill. Always block the wheels to prevent rolling.
Operating the ATV while the parking brake is engaged could
result in an accident and serious injury or death. Always check
to be sure the parking brake is disengaged before operating.
WARNING
1
2
42
FEATURES AND CONTROLS
Auxiliary Brake
The auxiliary brake (1), is
located on the inside of the right
floor board and is operated by
the right foot. The auxiliary
brake serves as a backup to the
main brake system if the main
system becomes inoperative.
If the rear wheels slide while
using the auxiliary brake, reduce
brake pedal pressure to brake the
rear wheels without skidding.
Check the brake fluid level frequently for the auxiliary brake system.
The reservoir is located under the seat or near the foot brake. Maintain
the fluid level between the maximum and minimum marks.
Aggressively applying the rear brake when backing down a hill
may cause rear tipover, which could result in serious injury or
death.
Use caution when applying the auxiliary brake. Do not
aggressively apply the auxiliary brake when going forward.
The rear wheels may skid and slide sideways, causing loss of
control and serious injury or death.
WARNING
1
43
FEATURES AND CONTROLS
Choke
The choke assists in starting a cold engine. Refer to the engine starting
procedure on page 51 for correct choke and throttle settings during
starting.
Fuel Valve
The fuel valve (1) is located on the left side of
the vehicle, below the fender. It has three
positions:
OFF: For vehicle storage and when transporting.
ON: For normal operation.
RES: For reserve supply if main
supply is exhausted.
NOTE: There’s about a 7 to 10 mile
(11.2 to 16 km) range on reserve gas.
Always refill the gas tank as soon as
possible after using the reserve supply.
Always return valve to ON position
after refueling.
Fuel Tank
The fuel tank filler cap (2) is located
directly below the handlebar. Use
either leaded or unleaded gasoline with
a minimum pump octane number of
87=(R+ M/2) octane. Refer to the
specifications section beginning on
page 107 for capacities.
Fuel Filter
The in-line fuel filter should be replaced by your dealer after every 100
hours of operation, or annually. Do not attempt to clean the fuel filter.
2
1
44
FEATURES AND CONTROLS
Fuel Safety
Gasoline is highly flammable and explosive under certain
conditions.
S
Always exercise extreme caution whenever handling gaso-
line.
S
Always refuel with the engine stopped, and outdoors or in a
well ventilated area.
S
Do not smoke or allow open flames or sparks in or near the
area where refueling is performed or where gasoline is
stored.
S
Do not overfill the tank. Do not fill the tank neck.
S
If gasoline spills on your skin or clothing, immediately wash it
off with soap and water and change clothing.
S
Never start the engine or let it run in an enclosed area.
Engine exhaust fumes are poisonous and can cause loss of
consciousness or death in a short time.
S
Turn the fuel valve off whenever the ATV is stored or parked.
The engine exhaust from this product contains chemicals
known to cause cancer, birth defects or other reproductive
harm.
Operate this vehicle only outdoors or in well-ventilated areas.
WARNING
WARNING
45
FEATURES AND CONTROLS
Oil Injection Tank
The oil injection tank filler cap (1)
is located on the front of the
vehicle. Refer to the specifications
section beginning on page 107
for capacities.
Mixing brands or using a non-recommended oil may cause
serious engine damage. We recommend the use of Polaris
Premium Synthetic 2-cycle oil for your 2-cycle Polaris ATV.
Never substitute or mix oil brands.
To avoid serious engine damage, always top off the oil level
when refueling.
CAUTION
1
46
FEATURES AND CONTROLS
Automatic Transmission Gear Selector
The transmission gear selector (1)
is located on the right side of the ATV.
F: Forward
N: Neutral
R: Reverse
Whenever the ATV is left unattended, always place the transmission in
gear and lock the parking brake.
1
F
N
R
Shifting gears with the engine speed above idle or while the
vehicle is moving could cause transmission damage.
To change gears, stop the vehicle, and with the engine idling,
move the lever to the desired gear.
CAUTION
47
FEATURES AND CONTROLS
Recoil Starter
If the battery has been drained or
damaged and cannot start the
engine, use of the recoil starter (1)
will allow vehicle operation until
repairs can be made. The recoil
starter is located on the right side
of the machine.
Polaris 4-cycle engines are
equipped with automatic
decompressors. This makes recoil
starting possible by reducing the
amount of compression during
starting. The decompressor senses when the engine is spinning fast
enough to start and restores compression when running.
1. Position the vehicle on a level surface and lock the parking brake
(see page 41).
2. Shift the transmission into neutral.
3. Make sure the engine stop switch is set to RUN and the main key
switch is in the ON position. NOTE: If the engine is cold, use the
choke as outlined on page 51.
4. Reach under the side panel and grasp the starter rope handle (2)
firmly and pull slowly so you can feel the engine strokes. NOTE:
Every other stroke will be a “compression stroke” and will make
the rope harder to pull. When a compression stroke is found,
continue pulling the rope just until the engine rolls past the stroke,
then stop pulling immediately.
5. Allow the recoil rope to rewind into the recoil assembly, then pull
the rope abruptly and forcefully to start the engine.
6. Repeat steps 4-5 if necessary.
1
2
Extending the recoil starter rope until it stops can cause damage
to the recoil assembly. Do not extend the starter rope so far that
it stops.
If the starter rope handle is not seated properly, water may enter
the recoil housing and damage components. Make sure the
handle is fully seated on the recoil housing, especially when
traveling in wet areas.
CAUTION
48
OPERATION
Break-In Period
The break-in period for your new Polaris ATV is defined as the time it
takes to use the first tank of fuel. No single action on your part is as
important as following the procedures for a proper break-in. Careful
treatment of a new engine will result in more efficient performance and
longer life for the engine. Perform the following procedures carefully.
CAUTION
Excessive heat build-up during the first three hours of
operation will damage close-fitted engine parts. Do not operate
at full throttle or high speeds for extended periods during the
first three hours of use.
Use of any oils other than those recommended by Polaris may
cause serious engine damage. We recommend the use of
Polaris 2-cycle oil for your 2-cycle engine.
Lack of proper lubrication will cause serious engine damage.
Always fill the oil tank when refueling the ATV.
49
OPERATION
Break-In Period
The first tank of fuel must be pre-mixed according to the following
instructions. After the break-in period, the oil injection system will
provide the necessary engine lubrication without pre-mixing.
1. Premix the recommended oil with gasoline in a suitable gas
container. Refer to the chart below for ratios.
2. Fill the fuel tank (see page 43), then fill the oil tank with the
recommended oil.
3. Drive slowly at first. Vary the throttle positions.
4. Perform regular checks on fluid levels, controls, and areas outlined
on the daily pre-ride inspection checklist on page 50.
After the first tank of pre-mixed fuel has been used, verify that the oil
level in the oil tank has dropped, indicating that the oil pump is
functioning properly. If the level has not dropped, see your dealer for
oil pump bleeding and repeat the pre-mix procedure.
Fuel/Oil Premix Chart
Fuel Oil @ 40:1
Gallons (Liters) Ounces (Liters)
1 (3.8) 3.2 (.09)
5 (18.9) 16 (.47)
10 (37.9) 32 (.95)
50
OPERATION
Pre-Ride Inspection
Use the following checklist to verify that your vehicle is in proper
working condition before each use.
Item/Inspection Procedure
1. Tires - Check condition and pressures.
2. Fuel and oil tanks - Fill both tanks to their proper levels.
3. Fluid levels - Inspect all other fluid levels.
4. All brakes - Check operation, adjustment and fluid level (includes
auxiliary brake).
5. Throttle - Check for free operation and closing.
6. Headlight/Taillight/Brakelight - Check operation of all indicator
lights and switches.
7. Engine stop switch - Check for proper function.
8. Wheels - Check for tightness of wheel nuts and axle nuts; check
that axle nuts are secured by cotter pins.
9. Drive chain - Check condition and slack (refer to drive chain
adjustment section); lubricate when needed.
10. Air cleaner element - Check for dirt; clean or replace.
11. Steering - Check for free operation, noting any unusual looseness
in any area.
12. Loose parts - Visually inspect vehicle for any damaged components
or loose nuts/bolts or fasteners.
13. Riding gear - Wear a helmet, goggles and protective clothing.
If a proper inspection is not done before each use, severe
injury or death could result. Always inspect the vehicle before
each use to ensure it’s in proper operating condition.
WARNING
51
OPERATION
Starting the Engine
Starting a Cold Engine
1. Place the transmission in neutral and
lock the parking brake. Make sure the
fuel valve is on.
2. Sit on the vehicle and pull the choke
knob (1) out until it stops. NOTE: If
the knob doesn’t stay where positioned,
increase the tension by rotating the tension
adjusting nut (2) clockwise.
NOTE: The variable choke is fully on when the
knob is pulled completely out. The choke is
off when the knob is pushed completely in.
The choke can be adjusted gradually, depending
on how much choke is needed for starting. Be
sure the choke is off during operation, as excess fuel
washing into the engine oil will increase wear on engine components.
3. Move the engine stop switch to RUN. NOTE: Do not press the
throttle while starting the engine.
4. Turn the ignition key past the ON position to engage the starter for
a maximum of five seconds. Release the key when the engine
starts. If it doesn’t start, release the key and wait five seconds.
Activate the starter for another five seconds. Repeat until the
engine starts.
5. If the engine slows or stops, position the choke knob half way in to
allow proper engine warm up.
6. Vary the engine RPM slightly with the throttle to aid in warm-up.
When the engine idles smoothly, push the choke all the way in.
Engine exhaust contains poisonous carbon monoxide and can
cause loss of consciousness resulting in severe injury or death.
Never run an engine in an enclosed area.
WARNING
Operating the vehicle immediately after starting could cause
engine damage. Allow the engine to warm up for several
minutes before operating the vehicle.
CAUTION
1
2
52
OPERATION
Starting the Engine
Starting a Warm Engine
Warm engines do not normally require the use of the choke. Excessive
use of the choke can cause the spark plug to become wet fouled.
1. Position the vehicle on a level surface and place the transmission in
neutral.
2. Lock the parking brake, turn the fuel tank valve to ON, sit on the
vehicle, and turn the engine stop switch to RUN.
3. If the engine has cooled to a point where it does not readily start,
intermittent use of the choke (pulled half way out) may be
necessary. NOTE: If the engine is over-choked when warm,
depress the throttle lever fully while cranking to aid in starting.
4. Release the throttle lever immediately after the engine starts. If the
engine does not start and all conditions are favorable, change the
spark plug and try again.
53
OPERATION
Driving Safely
Driving Procedures
1. Sit upright with both feet on the footrests and both hands on the
handlebars.
2. Start the engine and allow it to warm up, then 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 driving.
Vehicle speed is controlled by the amount of throttle opening.
6. Drive slowly. Practice maneuvering and using the throttle and brakes
on level surfaces.
54
OPERATION
Driving Safely
Making Turns
Your Polaris ATV is equipped with a solid rear axle that 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 make a 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.
NOTE: Practice making turns at slow speeds before attempting to turn
at faster speeds.
WARNING
Turning at sharp angles or at excessive speeds can result in
vehicle overturn and lead to serious injury. Avoid turning at
sharp angles. Never turn at high speeds.
55
OPERATION
Driving Safely
Driving on Slippery Surfaces
Whenever riding on slippery surfaces such as wet trails or loose gravel,
or during freezing weather, follow these precautions:
1. 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.
WARNING
Failure to exercise care when operating on slippery surfaces
can result in loss of tire traction and cause loss of control,
accident, and serious injury or death.
Never apply the brakes during a skid.
Do not operate on excessively slippery surfaces.
Always reduce speed and use additional caution.
56
OPERATION
Driving Safely
Driving Uphill
Whenever traveling uphill, follow
these precautions:
1. Always travel straight uphill.
2. Avoid steep hills (25_
maximum).
3. Keep both feet on the
footrests.
4. Transfer your weight forward.
5. Proceed at a steady rate of
speed and throttle opening.
6. Remain alert and be
prepared to take emergency
action. This may include
quick dismounting of the vehicle.
If all forward speed is lost:
Keep your weight uphill.
Apply the single lever brake, gradually. When fully stopped, apply the
auxiliary brake as well, then lock the park brake.
If the ATV begins rolling backwards:
Keep your weight uphill. Never apply engine power. Never apply the
auxiliary rear brake while rolling backwards.
Apply the single-lever brake, gradually. When fully stopped, apply the
auxiliary rear brake as well, and then lock the parking brake.
Dismount on uphill side, or to either side if ATV is pointed straight
uphill. Turn the ATV around and remount, following the procedure
described on page 59.
25_ Maximum
WARNING
Braking and handling are greatly affected when operating in
hilly terrain. Improper procedure could cause loss of control
or overturn and result in serious injury or death.
Avoid climbing steep hills (25_ maximum).
Use extreme caution when operating on hills, and follow
proper operating procedures outlined in the owner’s manual.
57
OPERATION
Driving Safely
Sidehilling
Sidehilling can be a dangerous type of driving and should be avoided if
at all possible. If you do enter into a situation where sidehilling is
necessary, follow these precautions:
1. Slow down.
2. Lean into the hill, transferring your upper body weight toward the hill
while keeping your feet on the footrests.
3. Steer slightly into the hill to maintain vehicle directions.
NOTE: If the vehicle begins to tip, quickly turn the front wheel
downhill, if possible, or dismount on the uphill side immediately!
Improperly crossing hills or turning on hills can result in loss of
control or vehicle overturn, resulting in severe injury or death.
Avoid crossing the side of a hill when possible. Follow proper
procedures as outlined in the owner’s manual.
WARNING
58
OPERATION
Driving Safely
Driving Downhill
Whenever descending a hill, follow these precautions:
1. Proceed directly downhill.
2. Transfer your weight to the rear of the vehicle.
3. Slow down.
4. Apply the brakes slightly to aid in slowing, using the single brake
lever.
NOTE: Familiarize yourself with operation of the auxiliary rear brake
pedal for additional braking in the event of normal service brake loss.
Excessive speed can cause loss of control and lead to serious
injury or death. Always operate slowly when traveling downhill.
WARNING
59
OPERATION
Driving Safely
Turning Around on a Hill
If the vehicle stalls while climbing a hill, never back it down the hill!
One maneuver that can be used when it’s necessary to turn around
while climbing a hill is the K-turn:
1. Stop and lock the parking brake while keeping body weight uphill.
2. Leave transmission in forward and shut off the engine.
3. Dismount on the uphill side of the vehicle, or on the left if the
vehicle is pointing straight uphill.
4. Staying uphill of the vehicle, turn the handlebars full left.
5. While holding the brake lever, release the parking brake lock and
slowly allow the vehicle to roll around to your right until it’s
pointing across the hill or slightly downward.
6. Lock the parking brake and remount the vehicle from the uphill
side, keeping body weight uphill.
7. Restart the engine with the transmission still in forward.
8. Release the parking brake and proceed slowly, controlling speed
with the brake, until the vehicle is on more level ground.
WARNING
Improper hill climbing procedures could cause loss of control
or overturn and result in serious injury or death.
Avoid climbing steep hills (25_ maximum).
Use extreme caution when operating on hills, and follow
proper operating procedures outlined in the owner’s manual.
8’
Uphill
60
OPERATION
Driving Safely
Driving Through Water
Your ATV can operate through water with a maximum recommended
depth equal to the bottom of the footrests (1). Follow these procedures
when operating through water:
1. Determine water depths and current before crossing.
2. Choose a crossing where both banks have gradual inclines.
3. Proceed slowly, avoiding rocks and obstacles if possible.
4. After crossing, dry the brakes by applying light pressure to the
lever until braking action is normal.
After running the vehicle in water, it’s critical to have it serviced as
outlined in the maintenance chart. See page 68. The following areas
need special attention: engine oil, transmission oil, front and rear
gearcases and all grease fittings.
1
61
OPERATION
Driving Safely
Driving Through Water
NOTE: Avoid operating the vehicle through deep or fast-flowing
water. If you cannot avoid water that exceeds the recommended
maximum depth, go slowly, balance your weight carefully, avoid
sudden movements, and maintain a slow and steady forward motion.
Do not make sudden turns or stops, and do not make sudden throttle
changes.
If your vehicle becomes immersed, and it’s impossible to take it to a
dealer before starting it, follow the steps described on page 95. Have
the vehicle serviced by your dealer at the first opportunity.
Major engine damage can result if the vehicle is not thoroughly
inspected after operation in water. Perform the services outlined
in the maintenance chart.
If your vehicle becomes immersed or is operated in water that
exceeds the footrest level, take it to your dealer for service
before starting the engine.
CAUTION
62
OPERATION
Driving Safely
Driving Over Obstacles
Be alert! Look ahead and learn to read the terrain you’re traveling on.
Be constantly alert for hazards such as logs, rocks and low hanging
branches.
Severe injury or death can result if your vehicle comes in
contact with a hidden obstacle. Not all obstacles are
immediately visible. Travel with caution in unfamiliar terrain.
WARNING
63
OPERATION
Driving Safely
Driving in Reverse
Follow these precautions
when operating in reverse:
1. Always avoid backing
downhill.
2. 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.
NOTE: Most Polaris ATVs are equipped with a reverse speed limiter.
The override button should be used with caution as rearward vehicle
speed is greatly increased. Do not operate at wide open throttle. Open
the throttle just enough to maintain a desired speed.
WARNING
Failure to use caution when operating in reverse can result in
serious injury or death. Before shifting into reverse, always check
for obstacles or people behind the vehicle. When it’s safe to
proceed, back slowly.
Do not use the override switch unless additional power is required
for vehicle movement. Use with caution.
Avoid backing on inclines, and avoid turning at sharp angles.
Excessive throttle operation while in the speed limit mode may
cause fuel to build in the exhaust, resulting in engine popping
and/or engine damage.
CAUTION
64
OPERATION
Hauling Cargo
Your ATV has been designed to carry or tow a certain amount of load
(if equipped with racks). Always read and understand the load
distribution warning labels on the vehicle, and never exceed the weight
capacities outlined in the specifications section of the owner’s manual
and on the safety decals.
Cargo weight should be evenly distributed (1/3 on the front rack and
2/3 on the rear rack) and mounted as low as possible. When operating
over rough or hilly terrain, reduce speed and cargo weight to maintain
stable driving conditions. Do not obstruct the headlight beam with
cargo.
2/3
1/3
65
OPERATION
Hauling Cargo
Hauling cargo improperly can alter vehicle handling and may
cause loss of control or brake instability and result in serious
injury or death. Always follow these precautions when hauling
cargo:
S REDUCE SPEED AND ALLOW GREATER DISTANCE FOR
BRAKING WHEN HAULING CARGO.
S CARGO WEIGHT DISTRIBUTION should be 1/3 on the front
rack and 2/3 on the rear rack. When operating over rough or
hilly terrain, reduce speed and cargo to maintain stable driv-
ing conditions. Carrying loads on one rack only increases the
possibility of vehicle overturn.
S LOADS MUST BE CARRIED AS LOW ON THE RACKS AS
POSSIBLE. Carrying loads high on the racks raises the cen-
ter of gravity of the vehicle and creates a less stable operat-
ing condition. When cargo loads are carried high on the
racks, the weight of the loads must be reduced to maintain
stable operating conditions.
S ALL LOADS MUST BE SECURED BEFORE OPERATING.
Unsecured loads can create unstable operating conditions,
which could result in loss of control of the vehicle.
S OPERATE ONLY WITH STABLE AND SAFELY ARRANGED
LOADS. When handling off-centered loads that cannot be
centered, securely fasten load and operate with extra cau-
tion. Always attach the tow load to the hitch point designated
for your vehicle.
S HEAVY LOADS CAN CAUSE BRAKING AND CONTROL
PROBLEMS. Use extreme caution when applying brakes
with a loaded vehicle. Avoid terrain or situations that may
require backing downhill.
S EXTREME CAUTION MUST BE USED when operating with
loads extending over the rack sides. Stability and maneuver-
ability may be adversely affected, causing the machine to
overturn.
S DO NOT BLOCK THE FRONT HEADLIGHT BEAM when
carrying loads on the front rack.
S DO NOT TRAVEL FASTER THAN THE RECOMMENDED
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 cornering, or while ascending or de-
scending a hill.
WARNING
66
OPERATION
Driving Safely
Parking on an Incline
Avoid parking on an incline if possible. If it’s unavoidable, follow
these precautions:
1. Turn the engine off.
2. Place the transmission in gear.
3. Set the parking brake.
4. Always block the rear wheels on the downhill side. See
illustration.
5. Shut off the fuel supply.
67
EMISSION CONTROL SYSTEMS
Noise Emission Control System
Do not modify the engine, intake or exhaust components, as doing so
may affect compliance with state and local noise level requirements.
Spark Arrestor
Your Polaris ATV has a spark arrestor that was tested and approved in
accordance with the USDA Forestry Service Standard 5100-1C.
Exhaust Emission Control System
The emissions from the exhaust of this vehicle are controlled by engine
design, including factory-set carburetion and ignition. The engine and
related components must be maintained at Polaris specifications to
achieve optimal performance.
Adjustment to engine idle is the
only adjustment Polaris
recommends that the operator
perform. Any other adjustments
should be performed by an
authorized Polaris dealer.
The emissions label (1) is
located on the recoil cover.
1
68
MAINTENANCE AND LUBRICATION
Accessories
Auxiliary power outlets provide 12V power for operating accessories
such as hand held spot lights. Accessory outlets are available for all
models. Contact your Polaris dealer for more information.
Polaris has a wide range of additional accessories available for your
ATV. See your Polaris dealer.
Periodic Maintenance Schedule
Careful periodic maintenance will help keep your vehicle in the safest,
most reliable condition. Inspection, adjustment and lubrication of
important components are explained in the periodic maintenance
schedule.
Maintenance intervals in the following charts are based upon average
riding conditions and an average vehicle speed of approximately 10
miles per hour. Vehicles subjected to severe use, such as operation in
wet or dusty areas, should be inspected and serviced more frequently.
Inspect, clean, lubricate, adjust and replace parts as necessary. When
inspection reveals the need for replacement parts, use genuine Polaris
parts available from your Polaris dealer.
NOTE: Service and adjustments are critical. If you’re not familiar
with safe service and adjustment procedures, have a qualified dealer
perform these operations.
Maintenance Chart Key
"
Perform these operations more often under severe use, such as in
dirty or wet conditions, to purge water or dirt contamination from
grease fittings and other critical components.
J
Dealer service item.
69
MAINTENANCE AND LUBRICATION
Periodic Maintenance Schedule
Hours of operation are based on a 10 mph average. If service is due at
20 hours, the equivalent odometer reading would be 200 miles.
Perform all services at whichever reading is reached first.
Item Hours/
Miles
Frequency Remarks
Brake System Pre-Ride Pre-Ride Inspect
Auxiliary Brake Pre-Ride Pre-Ride Inspect
Tires Pre-Ride Pre-Ride Inspect
Wheels Pre-Ride Pre-Ride Inspect
Frame nuts, bolts,
fasteners
Pre-Ride Pre-Ride Inspect
Oil level Pre-Ride Pre-Ride Check when refueling
"
Air filter,
Pre-cleaner
Pre-Ride Pre-Ride Inspect; clean
Coolant level Pre-Ride Pre-Ride Replace coolant every two
years
Fuel and oil tanks Pre-Ride Pre-Ride Fill to proper levels
Throttle Pre-Ride Pre-Ride Check operation
Lights Pre-Ride Pre-Ride Check operation
Engine stop switch Pre-Ride Pre-Ride Check operation
Drive chain Pre-Ride Pre-Ride Check condition/slack
Steering Pre-Ride Pre-Ride Check for free operation
"
Air box sediment
tube
Pre-Ride Pre-Ride Drain deposits whenever
visible
Headlamp Pre-Ride Pre-Ride Check operation daily; ap-
ply Polaris dielectric grease
to connector when replaced
"
More often under severe use, such as dirty or wet conditions
J
Dealer service item
Improperly performing the procedures marked with a
J
could
result in component failure and lead to serious injury or death.
Have an authorized Polaris dealer perform these services.
WARNING
70
MAINTENANCE AND LUBRICATION
Periodic Maintenance Schedule
Item Hours/
Miles
Frequency Remarks
Taillight/brakelight Pre-Ride Pre-Ride Check operation daily; ap-
ply Polaris dielectric grease
to socket when replaced
"
Air filter,
main element
Weekly Weekly Inspect; replace as needed
"
Transmission oil
level
20 hrs Monthly Inspect monthly; change
annually
Battery 20 hrs Monthly Check terminals; clean;
J
Brake pad wear 10 hrs Monthly Inspect periodically
Engine cylinder
head and cylinder
base fasteners
25 hrs 3 months Inspect (re-torque required
at first service only)
"
General lubrication 50 hrs 3 months Lubricate all fittings, pivots,
cables, etc.
Oil Pump Cable 50 hrs. 6 months Inspect, adjust, lubricate,
replace if required
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; lubricate;
replace if necessary
Choke (enricher)
cable
50 hrs. 6 months Inspect; adjust; lubricate;
replace if necessary
Shift linkage 50 hrs. 6 months Inspect; adjust
J
Drive belt 50 hrs. 6 months Inspect; replace as needed
"
Steering 50 hrs. 6 months Inspect daily; lubricate
"
Front suspension 50 hrs. 6 months Inspect; lubricate; tighten
fasteners
"
Rear suspension 50 hrs. 6 months Inspect; tighten fasteners
"
Drive chain(s) 50 hrs. 6 months Inspect daily; adjust and lu-
bricate if needed
"
Rear axle 50 hrs. 6 months Inspect bearings
"
More often under severe use, such as dirty or wet conditions
J
Dealer service item
71
MAINTENANCE AND LUBRICATION
Periodic Maintenance Schedule
Item Hours/
Miles
Frequency Remarks
Spark plug 100 hrs. 12 months Inspect; replace as needed
J
Ignition Timing 100 hrs. 12 months Inspect; adjust as needed
J
Fuel system 100 hrs. 12 months Check for leaks at tank
cap, lines, fuel valve, filter,
pump and carburetor; re-
place lines every two years
J
Fuel filter 100 hrs. 12 months Replace annually
J
Clutches
(drive and driven)
100 hrs. 12 months Inspect; clean
Engine mounts 100 hrs. 12 months Inspect
J
Oil filter 100 hrs. 12 months Replace
J
Shift selector box 200 hrs. 24 months Change lubricant every two
years
J
Brake fluid 200 hrs. 24 months Change every two years
Spark arrestor 300 hrs. 36 months Clean out
J
Front and rear
wheel bearings
300 hrs. 36 months Inspect; replace as needed
Idle speed As required Adjust
Recoil housing As required Drain moisture out after rid-
ing in water
J
Toe adjustment As required Periodic inspection; adjust
when parts are replaced
Headlight aim As required Adjust as needed
"
More often under severe use, such as dirty or wet conditions
J
Dealer service item
Improperly performing the procedures marked with a
J
could
result in component failure and lead to serious injury or death.
Have an authorized Polaris dealer perform these services.
WARNING
72
MAINTENANCE AND LUBRICATION
Periodic Maintenance Record
Use the following chart to record periodic maintenance.
Maintenance
Interval
Performed
Servicing
Date
Servicing
Dealer
or Person
Remarks
10 hrs.
20 hrs.
50 hrs.
100 hrs.
73
MAINTENANCE AND LUBRICATION
Lubrication Recommendations
NOTE: Hours are based on 10 mph average. If service is due at 20
hours, the equivalent odometer reading would be 200 miles. Perform
all services at whichever reading is reached first.
Lubrication Chart Key
"
More often under severe use, such as wet or dusty conditions
L
Polaris Premium All Season Grease or grease conforming to NLG
No. 2, such as Conoco Superlube M or Mobilegrease Special
∆
When suspension action becomes stiff, or after washing
Item Lube Method Frequency
Engine Polaris
Injection Oil
Fill oil tank. See page 45. As needed,
when refueling
Brakes DOT 3 fluid only Maintain level between fill
lines. See page 39.
As required; change
every two years or
200 hours
Drive chain(s) O-ring chain lube
or SAE 80/90
Lubricate as often as re-
quired. Before each ride in
wet conditions
As required
Transmission AGL Synthetic
Gearcase Lube
See Page 76. Check every 6
months/1000 miles.
Change annually or
at 100 hours
(1) Ball Joint
"
L
Grease
Locate fitting on back side of
struts and grease with
grease gun.
Every 3 months or
50 hours
(2) Swing Arm
Bushings
"
L
Grease
Locate fittings on swing arm
and grease with grease gun.
Monthly or at 20
hours
(2)
(1)
74
MAINTENANCE AND LUBRICATION
Lubrication Recommendations
Polaris 2-Cycle Lubricants
Polaris Premium 2-cycle lubricants are the most advanced formulation
of oils, specifically designed for today’s 2-cycle engines. These
lubricants provide additives for 2-cycle engines that are lacking in
today’s fuel. These necessary additives keep ring grooves cleaner for
less ring sticking and improved overall engine cleanliness.
With new generation lubricity technology, Polaris oils excel in meeting
the lubrication demands of today’s high performance 2-cycle engines.
We recommend the use of these optimum oils for Polaris liquid cooled
or air cooled 2-cycle engines.
Polaris premium 2-cycle oils will mix with each other, but consistent
performance will be enhanced by selecting only one of the premium
oils and maintaining regular use of that oil through the life of the unit.
Your dealer will be able to assist you with that selection, based on your
operating conditions and riding style.
Never mix Polaris premium 2-cycle oils with any other brand of oil,
including Polaris Nature Oil Biodegradable oil. Their incompatibility
could result in engine damage. For best performance, we recommend
that you choose one oil for your ATV, then continue to use it for the
life of the unit.
See page 110 for the part numbers of Polaris products.
Polaris VES II Synthetic 2-Cycle Oil
Your vehicle has been primed with VES II synthetic oil. We
recommend the continued use of this oil for your ATV. This lubricant
has been specially formulated for low smoke, low odor, low deposits
and high lubricity.
Premium 2-Cycle Oil
Polaris also has a TC-W3 premium oil or Premium Gold Synthetic Oil
suitable for use in all of our 2-cycle products.
CAUTION
Mixing brands or using a non-recommended oil may cause
serious engine damage. We recommend the use of Polaris
2-cycle oils for your 2-cycle engine. Never mix oil brands.
75
MAINTENANCE AND LUBRICATION
Lubrication Recommendations
Engine Oil Check
The oil tank cap (1) is located forward
of the headlight. Check the oil before
each use of the vehicle. Refill the oil
when refueling.
1. Position the ATV on a level
surface.
2. Remove the oil tank cap and
inspect the oil level in the tank.
3. Add oil as needed to bring the
level to the full mark. Do not
overfill.
4. Reinstall the oil tank cap.
1
76
MAINTENANCE AND LUBRICATION
Lubrication Recommendations
Transmission Oil Check
The transmission oil dipstick (1) is located
on the right side of the vehicle. Check the
transmission oil level monthly or every
1000 miles (1600 km), whichever comes
first. Maintain the transmission oil level in
the SAFE operating range (2). Change
transmission oil annually. We recommend
the use of AGL Synthetic Gearcase
Lubricant. See page 110 for the part
numbers of Polaris products.
1. Position the ATV on a level surface.
2. Remove the transmission oil dipstick
and wipe it clean.
3. Reinstall the dipstick, then remove it and read the
oil level. If the level is low, add the recommended gearcase oil to
bring the level within the safe operating range on the dipstick.
4. Reinstall the dipstick.
Transmission Oil Change
1. Place a drain pan beneath the
transmission oil drain plug area.
2. Loosen the jam nut (A).
3. Turn the adjuster bolt (B) in to
allow the removal of the drain
plug (C).
4. Remove the drain plug and wipe
the magnetic end clean to remove
accumulated metallic filings.
5. After the oil has drained
completely, install a new sealing
washer and reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm).
6. Turn the adjuster bolt (B) out until it touches the frame, and then
turn an additional 1/2 turn.
7. Tighten the jam nut securely while holding the adjuster bolt.
8. Add the recommended lubricant through the dipstick hole until the
oil level is between the upper and lower limits. Do not overfill.
9. Check for leaks.
1
2
A
B
C
77
MAINTENANCE AND LUBRICATION
Adjustments
Oil Pump Bleeding
1. Fill the oil tank with the
recommended oil. See page 110 for
the part numbers of Polaris
products.
2. Loosen the bleeder screw one full
turn. Allow oil to flow from the
bleed screw for five to ten seconds,
then tighten the bleed screw.
3. Start the engine and rotate the oil pump lever (2) to its full open
position. With the engine at idle, hold the lever up for thirty
seconds to purge all air from the system.
CAUTION
If the oil supply line has been disconnected from the pump, or if
the oil reservoir and supply line have been completely run out of
oil, the oil pump must be bled. If the pump is not bled, air in the
lines may prevent oil delivery to the engine, resulting in severe
engine damage.
1
2
CAUTION
Allowing the engine to run while the bleed screw is loose will
result in loss of oil, which will cause serious engine damage.
Always retighten the bleed screw if it’s been loosened for service.
78
MAINTENANCE AND LUBRICATION
Adjustments
Oil Pump
If it becomes necessary to increase oil flow into the fuel system, the oil
pump can be adjusted.
1. Before adjusting the oil pump, check the
engine idle RPM and carburetor settings
in the specifications section beginning
on page 107.
2. Loosen the throttle cable jam nut and
turn the adjuster (1) in or out until there
is 1/16″ - 1/8″ (.16 - .32 cm) of throttle
lever travel before the throttle slide starts
to open.
3. Place very slight pressure on the throttle
lever (2) until all freeplay is removed
from the throttle cable (to the point
where the carb slide is just starting to
rise).
4. Loosen the locknut (3).
Turn the adjuster in or out
until all freeplay is removed
from the oil pump cable (the
point where the oil pump
arm is just starting to move
off its stop). The pump stop
keeps the pump arm from
rotating any further down
than the idle position so no
visual alignment of marks is
necessary. Tighten the
locknut.
2
3
1
3
79
MAINTENANCE AND LUBRICATION
Adjustments
Brakes
The front and rear brakes are hydraulic disc brakes, activated by
moving the single brake lever toward the handlebar. These brakes are
self-adjusting.
The following checks are recommended to keep the brake system in
good operating condition. Check more often if brakes are used heavily
under normal operation, such as operation in hilly country or in muddy
terrain.
1. Always maintain brake fluid level as
recommended (see page 39).
2. Check the brake system for fluid
leaks.
3. Check the brakes for excessive travel
or spongy feel.
4. Check the friction pads for wear,
damage and looseness.
5. Check the security and surface
condition of the disc.
NOTE: Install new brake pads when pads
are worn to 3/64″ (.1 cm), or about the
thickness of a U.S. dime.
Auxiliary Brake
The auxiliary brake system is intended to be used as a backup for the
main brake system. Should the main system fail, the rear brake can be
activated by depressing the foot pedal on the inside of the right
footrest. The hydraulic auxiliary brake system requires no adjustment.
NOTE: Since this is a rear brake only, it will not be as effective as the
all-wheel single lever system.
3/64″ (.1 cm)
80
MAINTENANCE AND LUBRICATION
Adjustments
Toe Alignment
Use the following procedure to check the toe alignment of the vehicle.
The recommended toe alignment is 1/8″ to 1/4″ toe out.
1. Set the handlebars in a
straight-ahead position.
NOTE: The steering frog
can be used as an indicator
of whether the handlebars are
straight. The frog should
always point straight back
from the steering post.
2. Place stands (1) in front of
the vehicle, perpendicular to
the rear tires. See
illustration.
3. Tie an elastic string around
the stands, making sure the
string just touches the side
surface of the rear tires on
each side of the vehicle and
goes around the stands in
front of the vehicle (2).
4. Measure the distance from
the string to the rim at the
front and rear of the front
rim (3). Rear measurement should be 1/16″ - 1/8″ (.2 to .3 cm)
more than the front measurement.
NOTE: If you discover improper alignment, see your Polaris dealer
for service.
WARNING
Severe injury or death can result from improper toe alignment
and adjustment. Do not attempt to adjust tie rod alignment.
All tie rod adjustments should be performed by an authorized
Polaris dealer.
1
2
3
81
MAINTENANCE AND LUBRICATION
Adjustments
Steering Assembly
The steering assembly of the ATV should be checked periodically for
loose nuts and bolts. If loose nuts and bolts are found, see your Polaris
dealer for service before operating the vehicle.
Camber and Caster
The camber and caster are non-adjustable.
Rear Spring
The rear shock absorber spring is adjusted
by rotating the adjuster (1) either
clockwise or counterclockwise to increase
or decrease spring tension.
NOTE: Accessory springs are available
through your Polaris dealer.
1
82
MAINTENANCE AND LUBRICATION
Adjustments
Handlebars
The handlebars can be adjusted for
rider preference.
1. Remove the handlebar cover
and locate handlebar bolts (1).
2. Loosen the four bolts.
3. Adjust the handlebar to the
desired height. Be sure the
handlebars do not contact the
gas tank or any other part of the
machine when turned fully to the left or right.
4. Torque the front two bolts to 10-12 ft. lbs. (14-17 Nm), then torque
the rear two bolts. A gap of up to 1/8” will remain at the rear
bolts.
Throttle Cable Freeplay
Throttle cable freeplay is adjusted at the handlebar.
1. Slide the boots (1) off the inline cable adjuster sleeve (2). Loosen
the adjuster locknut (3).
2. Turn the adjuster until 1/16″ to 1/8″ freeplay is achieved at the
thumb lever. NOTE: While adjusting freeplay, be sure to flip the
throttle lever back and forth.
3. Tighten the locknut and slide the boots over the cable adjuster until
they touch at the midpoint of the adjuster.
Improper adjustment of the handlebars or incorrect torquing of
the adjuster block tightening bolts can cause limited steering or
loosening of the handlebars, resulting in loss of control and
possible serious personal injury or death. Follow the adjustment
procedures exactly, or see your Polaris dealer for service.
WARNING
1
12
1
3
83
MAINTENANCE AND LUBRICATION
Adjustments
Carburetor
IMPORTANT: Your Polaris ATV is calibrated at the factory for
optimal performance at altitudes ranging from zero to 6,000 feet (1800
m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above
6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and
the engine loses approximately 3% of its power for each 1000-foot
(304.8 m) increase in elevation. Although this power cannot be
regained, adjustments to the carburetor and drive system can be made
to allow more efficient operation. Optional jets, available from your
Polaris dealer, are required for operation above 6,000 feet and
temperatures below +40 degrees F. (4 degrees C.)
NOTE: Continuous operation of the engine without proper jetting
when required can cause poor performance, overheating or engine
damage. See your Polaris dealer for more information about jetting the
ATV for conditions in your area.
If the engine idle speed is not satisfactory, and all other conditions are
favorable, the carburetor can be adjusted.
1. Warm up the engine by running the
vehicle for approximately five
minutes.
2. Place the transmission in gear and lock
the parking brake.
3. Adjust the carburetor idle screw (1)
either in or out until the desired idle
RPM is reached. Turn the screw in
(clockwise) to raise RPM. Turn the
screw out (counterclockwise) to
lower RPM.
The following variations apply to air screw (2) adjustment for 2-cycle
engines:
S For improving cold weather start and reducing audible detonation
noise, the air screw can be closed from 1/2 to 1 turn by turning the
screw clockwise.
S During hot weather and/or high altitude operation the air screw can
be adjusted for smoother operation by turning the screw counter-
clockwise for approximately 2 turns.
1
2
84
MAINTENANCE AND LUBRICATION
Adjustments
Wheel Removal
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 vehicle
handling and could cause an accident resulting in serious injury
or death.
Maintain proper tire pressure as described on the decal on your
ATV and in your owner’s manual.
Always use original equipment size and type when replacing
tires.
Make sure the wheels are installed properly.
Always replace tires when the tread depth measures 1/8″ (.3 cm)
or less.
WARNING
85
MAINTENANCE AND LUBRICATION
Adjustments
Wheel Installation
1. Place the transmission in gear
and lock the parking brake.
2. Place the wheel on the wheel
hub with the valve stem toward
the outside and the rotation
arrows on the tire pointing
toward forward rotation.
3. Install the wheel nuts and finger
tighten.
4. Lower the vehicle to the ground.
5. Torque the wheel nuts according to the wheel nut torque
specifications chart.
NOTE: All nuts that have a cotter pin installed must be serviced by an
authorized Polaris dealer.
Wheel Nut Torque Specifications
Check the wheel nut torques occasionally and when they’ve been
loosened for maintenance service.
Bolt Size Specification
Front 3/8″ 20 ft. lbs. (27 Nm)
Rear 3/8″ 20 ft. lbs. (27 Nm)
Rear 1/2″ 50 ft. lbs. (68 Nm)
86
MAINTENANCE AND LUBRICATION
Adjustments
Front Wheel Hub Tightening
Front wheel bearing tightness and spindle nut retention are critical
component operations. All service must be performed by your
authorized Polaris dealer.
Tire Tread Depth
Always replace tires when tread
depth is worn to 1/8″ (.3 cm) or less.
See illustration.
1/8I (.3 cm)
WARNING
Operating the vehicle with worn tires will increase the possibility
of skidding, which could lead to loss of control and serious injury
or death. Always replace tires when the tread depth measures
1/8″ (.3 cm) or less.
Use of non-standard size or type of tires or improper tire
inflation may adversely affect vehicle maneuverability and
cause loss of control resulting in serious injury or death.
Maintain proper tire pressure as outlined in this owner’s
manual. When replacing a tire always use original equipment
size and type.
WARNING
87
MAINTENANCE AND LUBRICATION
Adjustments
Drive Chain
Polaris ATV drive chains are equipped with o-ring-sealed, permanently
greased pins and rollers. However, the outer surfaces of the roller must
be lubricated.
1. Always inspect the drive chain prior to operating the vehicle.
Check for damaged or missing o-rings or damaged rollers.
2. Check for correct slack adjustment.
3. Maintain the stone guard to rear sprocket clearance at 1/8″ (.3 cm).
4. Regularly lubricate the drive chain with Polaris chain lube or SAE
80-90 lube. See page 110 for the part numbers of Polaris products.
Cylinder Head/Cylinder Base Fastener
Have your dealer check the ATV cylinder head and cylinder base
fasteners for proper torque at the first service or after 25 hours.
Washing the drive chain with a high pressure washer or
gasoline can cause damage to the o-rings, causing premature
wear and drive chain failure. Don’t use a high pressure washer
or gasoline to clean the drive chain.
CAUTION
88
MAINTENANCE AND LUBRICATION
Adjustments
Rear Drive Chain Slack
Check the amount of chain slack in three different locations by moving
the vehicle slightly forward to gain slack at the top side of the rear
chain. Measure the chain slack at the tightest of the three positions. At
this point the chain should have 3/16″-3/8″ (.48 cm - .95 cm)
deflection. Use the following procedure if adjustment is required.
1. Loosen the chain guide.
2. Loosen the two eccentric
locking bolts (1).
3. Loosen the caliper mounting
bracket bolt located on the
left side of the swing arm.
4. Insert a pin punch (2)
through the sprocket hub
and into the eccentric
housing.
Adjusting or operating the ATV with improper rear drive chain
slack can result in severe damage to the transmission and drive
components. Always make sure the slack is within the stated
specifications.
CAUTION
3/16″-3/8″ (.48 cm - .95 cm)
1
2
1
89
MAINTENANCE AND LUBRICATION
Adjustments
Rear Drive Chain Slack
1. Roll the ATV forward or backward
to adjust the chain slack to the
proper tension. See the illustration
for proper splice link clip opening
position (1).
2. Tighten the eccentric locking bolts
to 30 ft. lbs. (41 Nm) for machines
without the hitch and 45 ft. lbs. (61
Nm) for machines with a hitch.
3. Tighten the caliper mount bolt to 10-12 ft. lbs. (14-17 Nm).
4. Remove the pin punch.
5. Roll the ATV forward, checking chain tension in several places
around the chain. NOTE: The chain is adjusted correctly when the
tightest portion of the chain has approximately 3/8” (10mm)
deflection.
6. Position the chain guide to allow 1/8” (3mm) clearance and tighten
the retaining bolt to 5 ft. lbs. (7 Nm).
7. Reinstall the chain guard if applicable.
1
90
MAINTENANCE AND LUBRICATION
Filter Systems
Air Filter Removal and Service
1. Remove the ATV seat.
2. Release the clips securing the cover assembly to the air box.
3. Loosen the clamp securing the filter, and remove the filter.
4. Remove the foam pre-filter from the main filter.
5. Wash the pre-filter in soapy water, then rinse and let dry.
6. Re-install the pre-filter over the main filter. (Replace the main filter
if needed.)
Air Filter Installation
1. Check the condition of the air box and replace if necessary.
2. Replace the filter over the carburetor boot. Make sure the filter is
fully seated in the air box.
3. Tighten the clamp. Do not overtighten, as filter damage could
occur.
4. Check the cover gasket and replace if needed. Be sure the cover is
seated properly, then snap the clips onto the cover.
5. Reinstall the ATV seat.
Air Filter Cleaning
NOTE: Always replace the main filter when it becomes dirty. In an
emergency situation, however, you may clean the main filter if you
observe the following practices.
1. Never immerse the main filter in water. Dirt can be transferred to
the clean air side of the filter.
2. If compressed air is used for cleaning, never exceed a pressure of
40 PSI. Always use a dispersion-type nozzle to prevent filter
damage, and blow the air from the inside to the outside.
NOTE: Replace the air filter every 50 hours and more often when the
vehicle is operated in very dirty conditions.
91
MAINTENANCE AND LUBRICATION
Lights
When servicing a halogen lamp, don’t touch the lamp with bare
fingers. Oil from your skin leaves a residue, causing a hot spot that
will shorten the life of the lamp.
Headlight Lamp Replacement
1. Remove the front cover and unplug the light harness.
2. Remove the rubber cap from the back of the headlight to reveal the
retention screw.
3. Remove the small phillips head screw, and carefully remove the
bulb from the housing.
4. Apply dielectric grease to the light bulb socket before installing the
new bulb. Insert the new bulb into the housing and reinstall the
retention screw. Reinstall the rubber cap.
5. Reconnect the light harness and reinstall the cover.
6. Adjust the headlight aim if necessary.
WARNING
Poor lighting while driving can result in severe injury or death.
Headlight and taillight lenses become dirty during normal
operation. Wash the headlights frequently to maintain lighting
quality.
Hot components can cause serious burns to skin. Do not
service the headlamps until they’ve cooled sufficiently.
92
MAINTENANCE AND LUBRICATION
Lights
Headlight Adjustment
1. Position the vehicle on
a level surface with the
headlight approximately
25 ft. (7.6 m) from a
flat wall.
2. Measure the distance
from the floor to the
center of the headlight
and make a mark on the
wall at the same height.
3. Start the engine and
turn on the headlight.
4. Observe the headlight
aim on the wall. The most intense part of the headlight beam
should be aimed 8” (20.3 cm) below the mark placed on the wall.
NOTE: Include rider weight on the seat when measuring.
5. Adjust the beam to the desired position by turning the adjustment
screws (1):
S Turning the right screw clockwise moves the intense spot of light up
and to the left.
S Turning the left screw clockwise moves the intense spot of the light
up and to the right.
S Turning the bottom screw clockwise adjusts the light upward.
1
1
93
MAINTENANCE AND LUBRICATION
Lights
Taillight/Brakelight Lamp Replacement
If the taillight/brakelight does not work the lamp may need to be
replaced.
1. Remove the taillight lens cover
mounting screws. Remove the
lens cover and gasket and set
aside for reassembly.
2. Remove the lamp (1) and
replace it with a new lamp.
3. Test the taillight/brakelight to
see that it’s working.
4. Reinstall the gasket and lens cover.
Indicator Lamp Replacement
1. Remove the instrument panel, if necessary, to access the back of
the indicator panel.
2. Using a small, straight-blade screwdriver, turn the base of the bulb
1/4 turn counterclockwise.
3. Using a needle-nose plier or similar tool, pull the lamp out of the
indicator panel housing.
4. Insert the new bulb and seat it by turning it 1/4 turn clockwise.
5. Reassemble the pod or front cover.
1
94
MAINTENANCE AND LUBRICATION
Spark Plugs
Always use the spark plugs recommended for your ATV. Refer to the
specifications section beginning on page 107 for the recommended spark
plug type and gap.
Spark plug condition is indicative of engine operation. The spark plug
firing end condition should be read after the engine has been warmed
up and the vehicle has been driven at higher speeds. Immediately
check the spark plug for correct color.
1. Normal
The normal insulator tip is gray, tan or light brown. There will be few
combustion deposits. The electrodes are not burned or eroded. This
indicates the proper type and heat range for the engine and the service.
NOTE: The tip should not be white. A white insulator tip indicates
overheating, caused by use of an improper spark plug or incorrect
carburetion adjustments.
2. Wet Fouled
The wet fouled insulator tip is black. A damp oil film covers the firing
end. There may be a carbon layer over the entire nose. Generally, the
electrodes are not worn. General causes of fouling are excessive oil,
use of non-recommended injection oil, improper use of the choke, or
incorrect carburetion adjustments.
Spark Plug Removal and Replacement
1. Remove the spark plug cap.
2. Using the special wrench provided in the tool pouch, rotate the
spark plug counterclockwise to remove.
3. Reverse the procedure for spark plug installation. Torque to 14 ft.
lbs. (19 Nm).
Using non-recommended spark plugs can result in serious
engine damage. Always use Polaris-recommended spark plugs.
CAUTION
WARNING
A hot exhaust system and engine can cause serious burns. Wear
protective gloves when removing a spark plug for inspection.
95
MAINTENANCE AND LUBRICATION
Vehicle Immersion
If it’s impossible to take your ATV to a dealer before starting it, follow
the steps outlined below.
1. Move the ATV to dry land or at the
very least, to water below the foot
rests.
2. Check the airbox for any water. Drain
and dry it if water is present.
3. Turn the fuel valve off.
4. Remove the spark plug.
5. Remove the bowl drain (1).
6. Remove the crankcase drain screw at
the left front of the engine bottom.
7. Turn the engine over several times
using the electric start.
8. Dry the spark plug and reinstall, or replace it with a new plug.
9. Reinstall the bowl drain.
10. Reinstall the crankcase drain screw.
11. Turn the fuel valve on.
12. Attempt to start the engine. If necessary, repeat the drying
procedure.
13. Take the ATV to your dealer for service as soon as possible,
whether you succeed in starting it or not.
NOTE: If water has been ingested into the PVT, follow the procedure
on page 99 for drying out the PVT.
If your vehicle becomes immersed, major engine damage can
result if the machine is not thoroughly inspected. Take the vehicle
to your dealer before starting the engine.
CAUTION
1
96
MAINTENANCE AND LUBRICATION
Spark Arrestor
1. Remove the arrestor clean-out
plug (1) from the bottom of the
muffler.
2. Place the transmission in neutral
and start the engine.
3. Purge carbon from the system by
momentarily revving the engine
several times.
4. If carbon is expelled, cover or plug the
exhaust outlet (2) and rap on the pipe around
the cleanout plug while revving the engine several more times.
5. If particles are still suspected to be in the muffler, elevate the rear
of the vehicle one foot higher than the front. Set the parking brake
and block the wheels. Make sure the vehicle is in neutral and
repeat steps 3 and 4 until no more particles are expelled when the
engine is revved.
6. Stop the engine and allow the arrestor to cool. Reinstall the
arrestor plug and remove the outlet cover or plug.
WARNING
Failure to heed the following warnings while servicing the spark
arrestor could result in serious injury or death.
Do not perform service on the spark arrestor while the system is
hot. Exhaust system temperatures can reach 1000° F. Allow
components to cool sufficiently before proceeding.
Remove any combustible materials from the area.
Wear eye protection.
Do not stand behind or in front of the vehicle while purging.
Never run the engine in an enclosed area. Exhaust contains
poisonous carbon monoxide gas.
Never go under the vehicle while it’s inclined.
1
97
MAINTENANCE AND LUBRICATION
Recoil Housing
To prevent possible engine damage,
always drain the recoil housing (1) after
operating the ATV in very wet
conditions. This should also be done
before storing the ATV.
Water will enter the recoil housing if
the starter handle is disengaged from
the rope guide when under water. The
recoil handle must be behind the heat
shield for it to seal properly.
The drain screw is located at the bottom of the recoil housing. Use a
wrench to remove the screw. Be sure to reinstall the screw after
draining the housing.
1
98
MAINTENANCE AND LUBRICATION
PVT System
The basic operation of the Polaris PVT system is dependent on engine
speed and vehicle torque requirements. As engine speed increases, the
force exerted on the movable drive sheave by the flyweights also
increases. This, in turn, increases the amount of “pinch” applied to the
drive belt. Similarly, if the engine speed decreases, the amount of
centrifugal force decreases, reducing the amount of belt “pinch.” This
begins to occur at speeds of less than 5 MPH, due to the system’s
dependence on engine speed.
For example, when operating at a ground speed of 3 MPH, the engine
would be running at only about 1500 RPM, with an engagement speed
of about 1400 RPM. Whenever operating this close to the engagement
point, the engine may be running at a speed too low to provide the
adequate “pinch” needed to prevent incomplete engagement.
Incomplete engagement creates excessive heat that can destroy belts
and clutch covers. In some cases, excessive clutch wear and damage
may result.
If the ATV will be operated for extended periods below 5 MPH, or for
towing loads, we recommend that you install a one tooth smaller
counter shaft sprocket to raise the operating RPM far enough above the
engagement RPM to reduce heat caused by incomplete engagement.
Reducing the temperature inside the clutch cover extends the life of the
PVT components (belt, cover, etc.).
NOTE: Avoid heavy pulling and extended low-speed operation.
99
MAINTENANCE AND LUBRICATION
PVT System
PVT Drying
There may be some instances when water is accidently ingested into
the PVT system. Use the following instructions to dry it out before
operating:
1. Remove the drain plug and allow the water to drain. Replace the
drain plug.
2. Start the engine and shift the transmission into neutral. Apply
varying throttle for 10-15 seconds to expel the moisture and air-dry
the belt and clutches. Do not hold the throttle wide open for more
than 10 seconds.
3. Allow the engine RPM to settle to idle speed, then shift the
transmission to the lowest available range.
4. Test for belt slippage. If the belt slips, repeat the process.
5. Take the vehicle to your dealer for service as soon as possible.
WARNING
Failure to comply with the instructions in this warning can result
in severe injury or death.
Do not modify any component of the PVT system. Doing so may
reduce its strength so that a failure may occur at a high speed.
The PVT system has been precision balanced. Any modification
will cause the system to be out of balance, creating vibration and
additional loads on components.
The PVT system rotates at high speeds, creating large amounts
of force on clutch components. Extensive engineering and
testing has been conducted to ensure the safety of this product.
However, as the owner, you have the following responsibilities to
make sure this system remains safe:
Always follow all recommended maintenance procedures. See
your dealer as outlined in the owner’s manual.
This PVT system is intended for use on Polaris products only. Do
not install it in any other product.
Always make sure the PVT housing is securely in place during
operation.
100
MAINTENANCE AND LUBRICATION
Battery
Battery Removal
1. Disconnect the battery hold-down strap and remove the battery cover.
2. Disconnect the black (negative) battery cable first.
3. Disconnect the red (positive) battery cable next.
4. Lift the battery out of the ATV.
Battery Installation
When installing a new battery, make sure it’s fully charged prior to its
initial use. Using a new battery that has not been fully charged can
damage the battery and result in a shorter life. It can also hinder
vehicle performance. Follow the battery charging instructions on page
101 before installing the battery.
1. Ensure that the battery is fully charged.
2. Set the battery in the battery holder.
3. Connect and tighten the red (positive) cable first.
4. Connect and tighten the black (negative) cable last.
5. Reinstall the battery cover and attach the hold-down strap.
6. Verify that cables are properly routed.
Improperly connecting or disconnecting battery cables can result
in an explosion and cause serious injury or death. When removing
the battery, always disconnect the negative (black) cable first.
When reinstalling the battery, always connect the negative (black)
cable last.
WARNING
101
MAINTENANCE AND LUBRICATION
Battery
Battery Storage
Whenever the vehicle is not used for a period of three months or more,
remove the battery from the vehicle, ensure that it’s fully charged, and
store it out of the sun in a cool, dry place. Check battery voltage each
month during storage and recharge as needed to maintain a full charge.
NOTE: Battery charge can be maintained by using a Polaris Battery
Tendert charger (PN 2871076) or by charging about once a month to
make up for normal self-discharge. Battery Tendert can be left
connected during the storage period, and will automatically charge the
battery if the voltage drops below a pre-determined point.
Battery Charging
The following battery charging instructions apply only to the
installation of a YUASA activated, sealed battery. Read all
instructions before proceeding with the installation of this battery.
The YUASA activated, sealed battery is already filled with electrolyte
and has been sealed and fully charged at the factory. Do not ever pry
the sealing strip off or add any other fluid to this battery.
The single most important thing about maintaining a sealed battery is
to keep it fully charged. Since the battery is sealed and the sealing strip
cannot be removed, you must use a voltmeter or multimeter to measure
DC voltage.
For a refresh charge, follow all instructions carefully.
1. Check the battery voltage with a voltmeter or multimeter. A fully
charged battery will register 12.8 V or higher.
2. If the voltage is less than 12.8 volts, recharge the battery at 1.2
amps or less until the battery voltage is 12.8 or greater.
NOTE: When using an automatic charger, refer to the charger
manufacturer’s instructions for recharging. When using a constant
current charger, use the following guidelines for recharging.
An overheated battery may explode, causing severe injury or
death. Always watch charging times carefully. Stop charging if
the battery becomes very warm to the touch. Allow it to cool
before resuming charging.
WARNING
102
MAINTENANCE AND LUBRICATION
Battery
Battery Charging
NOTE: Always verify battery condition before and 1-2 hours after the
end of charging.
State of
Charge
Voltage Action Charge Time*
(Using constant current
charger @ standard amps
specified on top of battery)
100% 12.8-13.0 volts None, check at
3 mos. from date of
manufacture
None required
75%-100% 12.5-12.8 volts May need slight
charge, if no
charge given,
check in 3 months
3-6 hours
50%-75% 12.0-12.5 volts Needs charge 5-11 hours
25%-50% 11.5-12.0 volts Needs charge At least 13 hours,
verify state of charge
0%-25% 11.5 volts or less Needs charge with
desulfating charger
At least 20 hours
103
MAINTENANCE AND LUBRICATION
Cleaning and Storage
See page 110 for the part numbers of Polaris products.
Cleaning the ATV
Keeping your ATV clean will not only improve its appearance but it
can also extend the life of various components. With a few
precautions, your ATV can be cleaned much like an automobile.
Washing the ATV
The best and safest way to clean your ATV is with a garden hose and a
pail of mild soap and water. Use a professional type washing mitten,
cleaning the upper body first and the lower parts last. Rinse with water
frequently and dry with a chamois to prevent water spots. NOTE: If
warning and safety labels are damaged, contact your a Polaris dealer
for free replacement.
Polaris does not recommend the use of a high pressure type car wash
system for washing the ATV. If a high pressure system is used,
exercise extreme care to avoid water damage to the wheel bearings,
transmission seals, body panels, brakes, warning labels and decals.
NOTE: Grease all zerk fittings immediately after washing, and allow
the vehicle to run for a while to evaporate any water that may have
entered the engine or exhaust system.
Waxing the ATV
Your ATV can be waxed with any non-abrasive automotive paste wax.
Avoid the use of harsh cleaners since they can scratch the body finish.
Certain products, including insect repellants and chemicals,
will damage plastic surfaces. Use caution when using these
products near plastic surfaces.
CAUTION
104
MAINTENANCE AND LUBRICATION
Cleaning and Storage
Storage Tips
See page 110 for the part numbers of Polaris products.
Exterior
Make necessary repairs and then clean the ATV thoroughly with mild
soap and warm water to remove all dirt and grime. Don’t use harsh
detergents or high pressure washers. Some detergents deteriorate rubber
parts. Use dish soap type cleaners only. High pressure washers may
force water past seals.
Fuel Stabilizer
Polaris Carbon Clean is a fuel stabilizer and fuel system dryer. It
cleans the fuel system, the combustion chamber and the exhaust ports.
It also prevents bacterial growth and promotes better starting after the
storage period.
1. Fill the fuel tank with fuel and add Polaris Carbon Clean or Fuel
Stabilizer. Follow the instructions on the container for the
recommended amounts.
2. Start the engine and allow it to run for 15-20 minutes so the stabilizer
can disperse through the fuel in the tank and carburetor.
3. Stop the engine, turn the fuel valve off, and drain the carburetor bowl.
Air Filter / Air Box
Inspect and clean or replace the pre-cleaner and air filter. Clean the air
box and drain the sediment tube.
Recoil Housing
Remove the recoil housing drain plug and drain any moisture.
Starting the engine during the storage period will disturb the
protective film created by fogging and damage could occur.
Never start the engine during the storage period.
CAUTION
105
MAINTENANCE AND LUBRICATION
Cleaning and Storage
Storage Tips
See page 110 for the part numbers of Polaris products.
Fluid Levels
Inspect the following fluid levels and change if necessary: engine oil;
transmission oil; brake fluid (change every two years or as needed if
fluid looks dark or contaminated).
Engine
Use Polaris Fogging Oil and follow the directions on the can.
If you choose not to use Polaris Fogging Oil, perform the following
procedure.
1. Support the front end of the machine so the engine is level or tilted
slightly rearward.
2. Remove the spark plug. Rotate the piston to BDC and pour
approximately two ounces of the recommended oil into the
cylinder. Reinstall the spark plug.
3. Apply dielectric grease to the inside of the spark plug cap and install
the cap onto the plug.
4. With the ignition off, turn the engine over several times using the
recoil starter. This will ensure coverage of the piston rings,
cylinder walls and crankshaft bearings.
5. Treat the fuel system with Polaris Carbon Clean.
6. If Polaris fuel system additive is not used, fuel tank, fuel lines, and
carburetor should be completely drained of gasoline.
Lubricate
Inspect all cables and lubricate with Polaris Cable Lubricant. Follow
lubrication guidelines in the maintenance section of the service or
owner’s manual to completely grease and lubricate the entire vehicle
with Polaris Premium All Season Grease. Apply Polaris O-Ring Chain
Lube to the drive chain.
106
MAINTENANCE AND LUBRICATION
Cleaning and Storage
Storage Tips
Battery Storage
Remove the battery from the vehicle and ensure that it’s fully charged
before placing it in storage. See page 101 for instructions.
Storage Area/Covers
Set the tire pressure and safely support the ATV with the tires 1-2” off
the ground. Be sure the storage area is well ventilated, and cover the
machine with a genuine Polaris ATV cover. NOTE: Do not use plastic
or coated materials. They do not allow enough ventilation to prevent
condensation, and may promote corrosion and oxidation.
Transporting an ATV
Follow these procedures when
transporting an ATV.
1. Turn off the engine and remove
the key to prevent loss during
transporting.
2. Turn the fuel valve off.
3. Be sure the fuel cap, oil cap and
seat are installed correctly and
securely.
4. Always tie the frame of the ATV
to the transporting unit securely
using suitable straps or rope. The
rack, bumper or handlebars do
not offer enough support for
tie-down while transporting the
unit.
5. Always place the transmission in
gear and lock the parking brake.
107
SPECIFICATIONS
2004 Trail Blazer
Capacities
Body Style Gen III
Gross Vehicle Weight 765 lbs. (347 kg)
Fuel Capacity 3.5 U.S. gal. (13.2 l)
Engine Oil 2 qts. (1.89 l)
Transmission Oil 32 oz. (.95 l)
Front Rack (Accessory)
(Maximum Capacity)
30 lbs. (13.6 kg)
Rear Rack (Accessory) 60 lbs. (27.2 kg)
Tongue Weight 85 lbs. (38.5 kg)
Tow Hitch Accessory
Tow Capacity 850 lbs. (385.5 kg)
Turn Radius 63 in. (160 cm)
Ground Clearance 5.5 (14 cm)
Height 47 in. (119.4 cm)
Length 75 in. (190.5 cm)
Seat Height 34 in. (86.4 cm)
Dry Weight 461 lbs. (209.1 kg)
Wheel Base 48 in. (121.9 cm)
Width 46 in. (116.8 cm)
Engine & Cooling
Engine Model Number / Type EC-25PFE-153 / 2 Cycle, Single Cylinder
Lubrication Oil Injection
Bore x Stroke 72 x 60
Displacement 244cc
Compression Ratio 6.1/1 Effective
Engine Cooling Air
Alternator Output 150 watts @ 4000 RPM
Carburetion 1/VM30SS
Main Jet 130 (hex)
Pilot Jet 40
Needle Jet 0-4 (169)
Pilot Screw 1.0
Jet Needle 5DP7-3
Ignition CDI
Timing 25° ± 3° @ 3000
Spark Plug Type / Gap NGK BR8ES / .028 in. (.7 mm)
108
SPECIFICATIONS
2004 Trail Blazer
Drive System
Drive System Type PVT
Shift Type Side Lever (F-N-R)
Gear Reduction - Low Not Applicable
Gear Reduction - Reverse 3.05/1
Gear Reduction - Forward 2.68/1
Front Drive (ratio) Not Applicable
Final Drive (ratio) 11/36 76P
Center Drive (ratio) Not Applicable
Drive Chain 520 O-Ring
Front Tire 23 x 7-10 (4 psi)
Rear Tire 22 x 11-10 (3 psi)
Suspension and Brakes
Front Suspension McPherson Strut w/8.2″ (20.8 cm) travel
Rear Suspension Progressive Rate w/10.5″ (26.7 cm) travel
Shock Adjustment CAM
Front Brake Hydraulic Disc
Rear Brake Hydraulic Disc
Auxiliary Brake Hydraulic Disc
Park Brake Hydraulic lock, all wheel
Features
Headlight 1 Single Beam (55 w)
Taillight 8.26 w
Brake Light 26.9 w
Battery 12V 14 AH
DC Plug-In (Rear) Accessory
DC Socket (Forward) Accessory
Electric Start Standard
High Temp Indicator Not Available
Windshield Accessory
Low Oil Light Standard
Neutral Indicator Standard
Reverse Indicator Standard
Speedometer Accessory
Fuel Gauge Standard
Tool Kit Standard
109
SPECIFICATIONS
2004 Trail Blazer
Jetting Chart
Altitude Ambient
Temperature
Below 0°F
(Below --18°C)
0° to 40°F
(--18°C to
+5°C)
+40° to +80°F
(+5°C to
+26°C)
+80°F & Above
(+26°C &
Above)
Meters
(
Feet
)
0-900
(0-3000)
150 140 130 120
(
F
e
e
t
)
900-1800
(3000-6000)
140 130 120 110
1800-2700
(6000-9000)
125 120 110 100
2700-3700
(9000-12000)
115 110 100 95
Turn air screw out 1/2 turn CCW from seat. Raise needle clip 1 position to lower jet needle.
Clutching Chart
Altitude Shift
Weight
Drive Clutch
Spring
Driven Clutch
Spring
Helix/Spring
Setting
Meters
(Feet)
0-1800
(0-6000)
G
(5630514)
Blue/Green
(7041157)
Red
(7041198)
40°
(5131446)
2+2
1800-3700
(6000-12000)
F
(5630515)
Blue/Green
(7041157)
Red
(7041198)
40°
(5131446)
2+2
110
POLARIS PRODUCTS
Part No. Description
Engine Lubricant
2870791 Fogging Oil (12 oz. Aerosol)
2871098 Premium 2-Cycle Engine Oil (qt.)
2871097 Premium 2-Cycle Engine Oil (gal.)
2871721 Premium Gold Synthetic 2-Cycle Oil (qt.)
2871722 Premium Gold Synthetic 2-Cycle Oil (gal.)
2874438 VES II Synthetic 2-Cycle Oil (qt.)
2874439 VES II Synthetic 2-Cycle Oil (gal.)
Gearcase / Transmission Lubricants
2873602 AGL Synthetic Gearcase Lubricant (qt.)
2873603 AGL Synthetic Gearcase Lubricant (gal.)
2873604 AGL Synthetic Gearcase Lubricant (2.5 gal.)
Grease / Specialized Lubricants
2871312 Grease Gun Kit, Premium All Season (3 oz.)
2871322 Premium All Season Grease (3 oz. cartridge)
2871423 Premium All Season Grease (14 oz. cartridge)
2872073 Chain Lube (6.25 oz. aerosol)
2872348 Chain Lube (16 oz. aerosol)
2871460 Starter Drive Grease (2 oz.)
2871329 Dielectric Grease (Nyogelt)
Additives / Miscellaneous
2872113 Disc Brake Quiet, Aerosol (9 oz.)
2871326 Carbon Clean Plus (12 oz.)
2870652 Fuel Stabilizer (16 oz.)
2870990 DOT3 Brake Fluid (12 oz.)
2872893 Engine Degreaser (12 oz.)
111
TROUBLESHOOTING
Drive Belt and Cover Problems
Possible Cause Solution
Driving the ATV onto a
pickup or tall trailer in
high range.
Avoid stopping on the ramp or creeping slowly up the
ramp. These practices may slip the clutch and belt.
Starting out going up a
steep incline.
When starting out on an incline, use low range or dis-
mount the ATV (after first applying the park brake) and
perform the K-turn as described on page 59.
Driving at low RPM or
low ground speed (at
approximately 3-7 MPH).
Drive at a higher speed. Avoid creeping.
Insufficient warm-up of
ATVs exposed to low am-
bient temperatures.
Warm the engine at least 5 minutes. With the transmission
in neutral, advance the throttle to about 1/8 throttle in
short bursts, 5 to 7 times. The belt will become more flex-
ible and prevent belt burning.
Slow and easy clutch en-
gagement.
Use the throttle quickly and effectively for efficient enga-
gement.
Towing/pushing at low
RPM/low ground speed.
Install a one tooth smaller counter shaft sprocket.
Stuck in mud or snow. Carefully use fast, aggressive throttle application to en-
gage clutch. WARNING: Excessive throttle may cause
loss of control and vehicle overturn.
Climbing over large ob-
jects from a stopped posi-
tion.
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.
Dry out the PVT as outlined on page 99. Inspect clutch
seals for damage if repeated leaking occurs.
Clutch malfunction. Contact your Polaris dealer for inspection of clutch com-
ponents.
Poor engine performance. Check for fouled plugs or foreign material in gas tank,
fuel lines, or carburetor. Contact your dealer for service.
112
TROUBLESHOOTING
Contact your Polaris dealer for service if you’re unable to identify
solutions using the following charts.
Engine Doesn’t Turn Over
Possible Cause Solution
Low battery voltage Recharge battery to 12.8 VDC
Loose battery connections Check all connections and tighten
Loose solenoid connections Check all connections and tighten
Engine Turns Over, Fails to Start
Possible Cause Solution
Out of fuel Turn fuel valve to reserve, refuel
Clogged fuel valve or filter Inspect and clean or replace
Water is present in fuel Drain the fuel system and refuel
Fuel valve is turned off Turn the fuel valve on
Old or non-recommended fuel Replace with new fuel
Fouled or defective spark plug(s) Inspect plug(s), replace if necessary
No spark to spark plug Inspect plug(s), verify stop switch is on
Crankcase filled with water or fuel Immediately see your Polaris dealer
Overuse of choke Inspect, clean and/or replace spark plugs
Clogged fuel filter Replace the filter
Low battery voltage Recharge battery to 12.8 VDC
Mechanical failure See your Polaris dealer
Engine Pings or Knocks
Possible Cause Solution
Poor quality or low octane fuel Replace with recommended fuel
Incorrect ignition timing See your Polaris dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
113
TROUBLESHOOTING
Engine Backfires
Possible Cause Solution
Weak spark from spark plugs Inspect, clean and/or replace spark plugs
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
Old or non-recommended fuel Replace with new fuel
Incorrectly installed spark plug wires See your Polaris dealer
Incorrect ignition timing See your Polaris dealer
Mechanical failure See your Polaris dealer
Engine Runs Irregularly, Stalls or Misfires
Possible Weak Spark Cause Solution
Fouled or defective spark plugs Inspect, clean and/or replace spark plugs
Worn or defective spark plug wires See your Polaris dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
Loose ignition connections Check all connections and tighten
Water present in fuel Replace with new fuel
Low battery voltage Recharge battery to 12.8 VDC
Kinked or plugged fuel vent line Inspect and replace
Incorrect fuel Replace with recommended fuel
Clogged air filter Inspect and clean or replace
Reverse speed limiter malfunction See your Polaris dealer
Electronic throttle control malfunction See your Polaris dealer
Other mechanical failure See your Polaris dealer
Possible Lean Fuel Mixture Cause Solution
Low or contaminated fuel Add or change fuel, clean the fuel system
Low octane fuel Replace with recommended fuel
Clogged fuel filter Replace filter
Incorrect jetting See your Polaris dealer
Possible Rich Fuel Mixture Cause Solution
Overuse of choke Inspect, clean and/or replace spark plugs
Fuel is very high octane Replace with lower octane fuel
Incorrect jetting See your Polaris dealer
114
TROUBLESHOOTING
Engine Stops or Loses Power
Possible Cause Solution
Out of fuel Turn fuel valve to reserve, refuel
Kinked or plugged fuel vent line Inspect and replace
Water present in fuel Replace with new fuel
Overuse of choke Inspect, clean and/or replace spark plugs
Fouled or defective spark plugs Inspect, clean and/or replace spark plugs
Worn or defective spark plug wires See your Polaris dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
Loose ignition connections Check all connections and tighten
Low battery voltage Recharge battery to 12.8 VDC
Incorrect fuel Replace with recommended fuel
Clogged air filter Inspect and clean or replace
Reverse speed limiter malfunction See your Polaris dealer
Electronic throttle control malfunction See your Polaris dealer
Other mechanical failure See your Polaris dealer
Overheated engine Clean engine exterior
See your Polaris dealer
115
WARRANTY
LIMITED WARRANTY
Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED
WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects
in material or workmanship. Polaris also gives a one year limited warranty on the final drive
chain for failure due to defects. This warranty covers the parts and labor charges for repair
or replacement of defective parts which are covered by this warranty. This warranty begins
on the date of purchase. This warranty is transferrable to another consumer during the war-
ranty period through a Polaris dealer.
REGISTRATION
At the time of sale, the Warranty Registration Form must be completed by your dealer and
submitted to Polaris within ten days. Upon receipt of this registration, Polaris will record
the registration for warranty. THE PURCHASER MUST COMPLETE AN ATV SAFETY
TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID
WARRANTY ON THE ATV. No verification of registration will be sent to the purchaser
as the copy of the Warranty Registration Form will be the warranty entitlement. If you have
not signed the original registration and received the “customer copy”, please contact your
dealer immediately. NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS
YOUR ATV IS REGISTERED WITH POLARIS.
Initial dealer preparation and set-up of your ATV is very important in ensuring trouble-free
operation. Purchasing a machine in the crate or without proper dealer set-up will void your
warranty coverage.
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 al-
tered structurally, modified, neglected, improperly maintained, used for racing, or used for
purposes other than for which it was manufactured, or for any damages which occur during
trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addi-
tion, this warranty does not cover physical damage to paint or finish, stress cracks, tearing
or puncturing of upholstery material, corrosion, or defects in parts, components or the 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 exclusive remedy for breach of this warranty shall be, at
Polaris’ exclusive 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 INCIDENTAL,
CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER
ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CON-
TRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. Some states do not per-
mit the exclusion or limitation of incidental or consequential damagesor implied warranties,
so the above limitations or exclusions may not apply to you if inconsistent with controlling
state law.
116
WARRANTY
WARRANTY COVERAGE AND EXCLUSIONS:
LIMITATIONS OF WARRANTIES AND REMEDIES
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRAN-
TY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT
STATED IN THIS WARRANTY. Some states do not allow limitations on how long an im-
plied warranty lasts, so the above limitation may not apply to you if inconsistent with con-
trolling state law.
HOW TO OBTAIN WARRANTY SERVICE
If your ATV requires warranty service, you must take it to a Polaris dealer authorized to re-
pair Polaris ATVs. When requesting warranty service you must present your copy of the
Warranty Registration form to the dealer. (THE COST OF TRANSPORTATION TO AND
FROM THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests that you use your
original selling dealer; however, you may use any Polaris Servicing Dealer to perform war-
ranty service.
Please work with your dealer to resolve any warranty issues. Should your dealer require any
additional assistance they will contact the appropriate personnel at Polaris.
This warranty gives you specific legal rights, and you may also have other rights which vary
from state to state.
If any of the above terms are void because of state or federal law, all other warranty terms
will remain in effect.
Engine Oil
1. Mixing oil brands or using non-recommended oil may cause engine damage. We recom-
mend the use of Polaris engine oil.
2. Damage resulting from the use of non-recommended lubricants may not be covered by
warranty.
117
WARRANTY
Exported Vehicles
EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-
RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD
OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCA-
TION.
This policy does not apply to vehicles that have received authorization for export from
Polaris Industries. Dealers may not give authorization for export. You should consult an
authorized dealer to determine this vehicle’s warranty or service bulletin coverage if you
have any questions.
This policy does not apply to vehicles registered to government officials or military per-
sonnel on assignment outside the country of the selling dealer’s authorized location.
This policy does not apply to Safety Recalls.
How to Get Service
In the Country where your vehicle was purchased:
Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you
move or are traveling within the country where your vehicle was purchased, Warranty or
Service Bulletin repairs may be requested from any authorized Polaris dealer who sells
the same line as your vehicle.
Outside the Country where your vehicle was purchased:
If you are traveling temporarily outside the country where your vehicle was purchased,
you should take your vehicle to an authorized Polaris dealer. You must show the dealer
photo identification from the country of the selling dealer’s authorized location as proof
of residence. Upon residence verification, the servicing dealer will be authorized to per-
form the warranty repair.
If You Move:
If you move to another country, be sure to contact Polaris Customer Assistance and the
customs department of the destination country before you move. Vehicles importation
rules vary considerably from country to country. You may be required to present docu-
mentation of your move to Polaris Industries in order to continue your warranty cover-
age. You may also be required to obtain documentation from Polaris Industries in order
to register your vehicle in your new country.
How to Get Service
If Purchased From A Private Party:
If you purchase a Polaris product from a private citizen outside of the country in which
the vehicle was originally purchased, all warranty coverage will be denied.
Notice
If your vehicle is registered outside of the country where it was purchased, and you have
not followed the procedure set out above, your vehicle will no longer be eligible for war-
ranty or service bulletin coverage of any kind. (Vehicles registered to Government offi-
cials or military personnel on assignment outside of the country where the vehicle was
purchased will continue to be covered by the basic warranty.)
For questions call Polaris Customer Assistance:
United States: 1-763-417-8650
Canada: 1-204-925-7100
118
INDEX
A
Accessories 68. . . . . . . . . . . . . . . . . . .
Adjustments 77-89. . . . . . . . . . . . . . . .
Age Restrictions 7. . . . . . . . . . . . . . . .
Air Filter 90. . . . . . . . . . . . . . . . . . . . .
Auxiliary Brake 42, 79. . . . . . . . . . . .
B
Battery 100-102. . . . . . . . . . . . . . . . . .
Battery Charging 101-102. . . . . . . . . . .
Battery Installation 100. . . . . . . . . . . .
Battery Removal 100. . . . . . . . . . . . . .
Battery Storage 101, 106. . . . . . . . . . .
Brake Lever 40. . . . . . . . . . . . . . . . . .
Brakes 39, 79. . . . . . . . . . . . . . . . . . . .
Break-In Period 48-49. . . . . . . . . . . . . .
C
Camber and Caster 81. . . . . . . . . . . . .
Carburetor 83. . . . . . . . . . . . . . . . . . . .
Choke 43. . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Storage 103-106. . . . . . .
Cleaning the ATV 103. . . . . . . . . . . . .
Clutching Chart 109. . . . . . . . . . . . . . .
CONTROLS 36-47. . . . . . . . . . . . . . . .
Cylinder Head/
Cylinder Base Fastener 87. . . . . .
D
Drive Chain 87. . . . . . . . . . . . . . . . . .
Driving Downhill 58. . . . . . . . . . . . . .
Driving in Reverse 63. . . . . . . . . . . . .
Driving on Slippery Surfaces 55. . . . .
Driving Over Obstacles 62. . . . . . . . . .
Driving Procedures 53. . . . . . . . . . . . .
Driving Safely 53-66. . . . . . . . . . . . . . .
Driving Through Water 60-61. . . . . . . .
Driving Uphill 56. . . . . . . . . . . . . . . .
E
Electrical Switches 36. . . . . . . . . . . . .
EMISSION CONTROL SYSTEMS 67
Engine Fogging 105. . . . . . . . . . . . . .
Engine Oil Check 75. . . . . . . . . . . . . .
Equipment Modifications 11. . . . . . . .
Exhaust Emission Control System 67.
F
FEATURES 36-47. . . . . . . . . . . . . . . .
Filter Systems 90. . . . . . . . . . . . . . . . .
Front Wheel Hub Tightening 86. . . . .
Fuel Filter 43. . . . . . . . . . . . . . . . . . . .
Fuel Safety 44. . . . . . . . . . . . . . . . . . .
Fuel Stabilizer 104. . . . . . . . . . . . . . . .
Fuel Tank 43. . . . . . . . . . . . . . . . . . . .
Fuel Valve 43. . . . . . . . . . . . . . . . . . . .
G
Gear Selector 46. . . . . . . . . . . . . . . . . .
H
Handlebars 82. . . . . . . . . . . . . . . . . . .
Hauling Cargo 64-65. . . . . . . . . . . . . . .
Headlight Adjustment 92. . . . . . . . . . .
Headlight Lamp Replacement 91. . . . .
I
Indicator Lamp Replacement 93. . . . .
Indicator Lights 38. . . . . . . . . . . . . . . .
J
Jetting Chart 109. . . . . . . . . . . . . . . . .
K
K-Turn 59. . . . . . . . . . . . . . . . . . . . . .
L
Light Switches 38. . . . . . . . . . . . . . . .
Lights 91-93. . . . . . . . . . . . . . . . . . . . .
Lubrication Recommendations 73-76. .
Lubricants, 2-Cycle 74. . . . . . . . . . . . .
LUBRICATION 68-106. . . . . . . . . . . .
M
Main Switch 36. . . . . . . . . . . . . . . . . .
MAINTENANCE 68-106. . . . . . . . . .
Maintenance Record 72. . . . . . . . . . . .
Maintenance Schedule 68-71. . . . . . . .
Making Turns 54. . . . . . . . . . . . . . . . .
N
Noise Emission Control System 67. . .
119
INDEX
O
Oil 74. . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Injection Tank 45. . . . . . . . . . . . . .
Oil Pump Adjustment 78. . . . . . . . . . .
Oil Pump Bleeding 77. . . . . . . . . . . . .
OPERATION 48-66. . . . . . . . . . . . . . .
Operator Safety 7-31. . . . . . . . . . . . . . .
Override Switch 36. . . . . . . . . . . . . . .
P
Parking Brake 41. . . . . . . . . . . . . . . . .
Parking on an Incline 66. . . . . . . . . . .
POLARIS PRODUCTS 110. . . . . . . .
Pre Ride Inspection 50. . . . . . . . . . . . .
PVT Drying 99. . . . . . . . . . . . . . . . . .
PVT System 98-99. . . . . . . . . . . . . . . .
R
Rear Drive Chain Slack 88-89. . . . . . . .
Rear Spring 81. . . . . . . . . . . . . . . . . . .
Recoil Housing 97. . . . . . . . . . . . . . . .
Recoil Starter 47. . . . . . . . . . . . . . . . .
S
Safe Riding Gear 35. . . . . . . . . . . . . . .
SAFETY 7-35. . . . . . . . . . . . . . . . . . . .
Safety Decals and Locations 32-34. . . .
Safety Training 7. . . . . . . . . . . . . . . . .
Sidehilling 57. . . . . . . . . . . . . . . . . . .
Spark Arrestor 96. . . . . . . . . . . . . . . . .
Spark Plug Removal
and Replacement 94. . . . . . . . . . .
Spark Plugs 94. . . . . . . . . . . . . . . . . . .
SPECIFICATIONS 107-109. . . . . . . . .
Starting a Cold Engine 51. . . . . . . . . .
Starting a Warm Engine 52. . . . . . . . .
S
Starting the Engine 51-52. . . . . . . . . . .
Steering Assembly 81. . . . . . . . . . . . .
Stop Switch 36. . . . . . . . . . . . . . . . . . .
Storage Tips 104-106. . . . . . . . . . . . . .
T
TABLE OF CONTENTS 5. . . . . . . . .
Taillight/Brakelight
Lamp Replacement 93. . . . . . . . .
Throttle Cable Freeplay 82. . . . . . . . . .
Throttle Lever 37. . . . . . . . . . . . . . . . .
Tire Tread Depth 86. . . . . . . . . . . . . . .
Toe Alignment 80. . . . . . . . . . . . . . . .
Transmission Gear Selector 46. . . . . . .
Transmission Oil Change 76. . . . . . . .
Transmission Oil Check 76. . . . . . . . .
Transporting an ATV 106. . . . . . . . . .
TROUBLESHOOTING 111-114. . . . .
Turning Around on a Hill 59. . . . . . . .
U
USFS Approved Spark Arrestor 67. . .
V
VEHICLE IDENTIFICATION
NUMBERS 6. . . . . . . . . . . . . . . .
Vehicle Immersion 95. . . . . . . . . . . . .
W
WARRANTY 115-117. . . . . . . . . . . . .
Washing the ATV 103. . . . . . . . . . . . .
Waxing the ATV 103. . . . . . . . . . . . . .
WELCOME 3. . . . . . . . . . . . . . . . . . .
Wheel Installation 85. . . . . . . . . . . . . .
Wheel Nut Torque Specifications 85. .
Wheel Removal 84. . . . . . . . . . . . . . .
