Read this manual carefully. It contains important safety information.
This is an adult vehicle only.
Operation is prohibited for those under 16 years of age.
Owner's Manual
for Maintenance and Safety
Hawkeye 400 H.O. 2X4
The text is printed on 100% recycled
with 40% post-consumer waste (PCW).
1
WELCOME
Thank you for purchasing a POLARIS vehicle, and welcome to our
world-wide family of POLARIS owners. We proudly produce an excit-
ing line of utility and recreational products.
• Snowmobiles
• All-terrain vehicles (ATVs)
• RANGER
®
utility vehicles
• Victory Motorcycles
®
• Low emission vehicles (LEVs)
Always follow the instructions and recommendations in this manual.
The manual contains instructions for minor maintenance, but informa-
tion about major repairs is outlined in the POLARIS Service Manual
and should be performed only by a factory certified Master Service
Dealer
®
(MSD) technician. Please see your dealer for all of your service
needs during (and after) the warranty period.
For more information about POLARIS, visit us online at
www.polarisindustries.com.
2
POLARIS, THE WAY OUT and HAWKEYE are registered trademarks of POLARIS
Industries Inc.
Copyright 2011 POLARIS Sales Inc. All information contained within this publication
is based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrep-
ancies may result between the actual vehicle and the information presented in this publi-
cation. Depictions and/or procedures in this publication are intended for reference use
only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse
of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.
The original instructions for this vehicle are in English. Other languages are provided as
translations of the original instructions.
Printed in U.S.A.
2012 HAWKEYE 400 2X4 Owner’s Manual
P/N 9923552
3
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Features and Controls . . . . . . . . . . . . . . . . . . . 24
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Emission Control Systems . . . . . . . . . . . . . . . 59
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 109
POLARIS Products. . . . . . . . . . . . . . . . . . . . . 113
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 114
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 119
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4
INTRODUCTION
The following signal words and symbols appear throughout this manual
and on your vehicle. Your safety is involved when these words and sym-
bols are used. Become familiar with their meanings before reading the
manual.
The safety alert symbol indicates a potential personal injury hazard.
WARNING
A WARNING indicates a hazardous situation which, if not avoided, may result in
death or serious injury.
CAUTION
A CAUTION indicates a hazardous situation which, if not avoided, may result in
minor or moderate injury.
NOTICE
A NOTICE indicates a situation that may result in property damage.
The Prohibition Safety Sign indicates an action NOT to take in order
to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to be
taken to avoid a hazard.
5
INTRODUCTION
Failure to follow the warnings in this manual can result in serious injury or death.
This POLARIS vehicle is not a toy and can be hazardous to operate. A collision
or rollover can occur quickly, even during routine maneuvers, if you fail to take
proper precautions.
Read and understand your owner's manual and all warnings before operating
this POLARIS vehicle.
European Vibration and Noise
The driver-perceived noise and hand/arm and whole body vibration lev-
els of this machinery is measured per prEN 15997.
The operating conditions of the machinery during testing:
The vehicles were in like-new condition. The environment was con-
trolled as indicated by the test procedure(s).
The uncertainty of vibration exposure measurement is dependent on
many factors, including:
• Instrument and calibration uncertainty
• Variations in the machine such as wear of components
• Variation of machine operators such as experience or physique
• Ability of the worker to reproduce typical work during measurements
• Environmental factors such as ambient noise or temperature
WARNING
6
INTRODUCTION
Vehicle Identification Numbers
Record your vehicle's identification numbers and key number in the
spaces provided. Remove the spare key and store it in a safe place. An
ignition key can be duplicated only by ordering a POLARIS key blank
(using your key number) and mating it with one of your existing keys.
The ignition switch must be replaced if all keys are lost.
Vehicle Model Number: ___________________________________________________
Frame VIN: ____________________________________________________________
Engine Serial Number: ___________________________________________________
Key Number: ___________________________________________________________
####
Engine Serial Number
Key Number
VIN
(front or rear frame)
7
SAFETY
Safety Training
Never operate this vehicle without proper instruction. Take a training
course.
For more information about safety, contact an authorized POLARIS
dealer or visit the POLARIS web site at www.polarisindustries.com.
Restrictions
This vehicle is approved for OFF-ROAD TOWING ONLY. Towing a
trailer with this vehicle on public roads is prohibited.
Equipment Modifications
The warranty on your POLARIS vehicle may be terminated if any
equipment has been added, or if any modifications have been made, that
increase speed or power. The addition of certain accessories, including
(but not limited to) mowers, blades, tires, sprayers and large racks may
change vehicle handling. Use only POLARIS-approved accessories.
Know their function and effect on the vehicle.
8
SAFETY
Safe Riding Gear
Always wear appropriate clothing when riding an ATV. Wear protective
clothing for comfort and to reduce the chance of injury.
Helmet
Wearing a helmet can prevent a severe head injury. Whenever riding a
POLARIS vehicle, always wear a helmet that meets or exceeds estab-
lished safety standards.
Approved helmets in the USA and Canada bear a U.S. Department of
Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania
bear the ECE 22.05 label. The ECE mark consists
of a circle surrounding the letter E, followed by the
distinguishing number of the country which has
granted approval. The approval number and serial
number will also be displayed on the label.
Helmet
Eye Protection
Gloves
Boots
Long Pants
Long
Sleeves
E
4
051039
0006.31
9
SAFETY
Safe Riding Gear
Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection. When-
ever riding a POLARIS vehicle, always wear shatterproof goggles or
use a shatterproof helmet face shield. POLARIS recommends wearing
approved Personal Protective Equipment (PPE) bearing markings such
as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept
clean.
Gloves
Off-road style gloves with knuckle pads are the best for comfort and
protection.
Boots
The best footwear is a pair of sturdy over-the-calf boots with low heels.
Clothing
Always wear long sleeves and long pants to protect arms and legs. Rid-
ing pants with kneepads and a jersey with shoulder pads provide the best
protection.
10
SAFETY
Safety Warnings
Failure to operate the ATV properly can result in a collision, loss of control,
accident or overturn, which may result in serious injury or death. Heed all safety
warnings outlined in this section of the owner’s manual. See the OPERATION
section of the owner’s manual for proper operating procedures.
Operating Without Instruction
Read and understand all warnings, cautions and
operating procedures in this manual and on the
safety labels before operating this vehicle.
Never operate this vehicle without proper
instruction. Take a training course. Beginners
should receive training from a certified instructor.
Never permit others to operate this vehicle unless
they have read and understand this manual and all
product labels, and have completed a certified
safety training course.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY.
Operation is prohibited for anyone under 16 years
of age.
WARNING
11
SAFETY
Safety Warnings
Handling Gasoline
Gasoline is highly flammable and explosive under certain conditions.
• Always exercise extreme caution whenever handling gasoline.
• Always refuel with the engine stopped, and outdoors or in a well ventilated
area.
• Do not smoke or allow open flames or sparks in or near the area where refu-
eling is performed or where gasoline is stored.
• Do not overfill the tank. Do not fill the tank neck.
• If gasoline spills on your skin or clothing, immediately wash it off with soap
and water and change clothing.
• Turn the fuel valve off whenever the vehicle is stored or parked.
Exposure to Exhaust
Engine exhaust fumes are poisonous and can cause loss of consciousness or
death in a short time. Never start the engine or let it run in an enclosed area.
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.
Failure to Inspect Before Operating
Failure to inspect and verify that the ATV is in safe
operating condition before operating increases the
risk of an accident.
Always inspect the ATV before each use to make
sure it's in safe operating condition.
Always follow all inspection and maintenance
procedures and schedules described in the
owner's manual.
12
SAFETY
Safety Warnings
Protective Apparel
Riding in this vehicle without wearing an
approved helmet and protective eyewear
increases the risk of a serious injuries in the
event of an accident.
Operator and passenger must always wear an
approved helmet that fits properly and eye
protection (goggles or face shield).
Using Alcohol or Drugs
Operating the ATV after consuming
alcohol or drugs could adversely affect
operator judgment, reaction time,
balance and perception.
Never consume alcohol or drugs before
or while operating an ATV.
Carrying a Passenger
Carrying a passenger greatly reduces the
operator's ability to balance and control the
ATV, which may result in an accident or
overturn.
Never carry a passenger on this ATV.
13
SAFETY
Safety Warnings
Operating on Pavement
Operating an ATV on paved surfaces
(including sidewalks, paths, parking lots and
driveways) may adversely affect the
handling of the ATV and could result in loss
of control and accident or overturn.
Avoid operating the ATV on pavement. ATV
tires are designed for off-road use. If it's
unavoidable, travel slowly and avoid sudden
turns or stops.
Operating on Public Roads
Operating this ATV on public streets, roads
or highways could result in a collision with
another vehicle.
Never operate the ATV on any public street,
road or highway, including dirt and gravel
roads. In many states it's unlawful to
operate ATVs on public streets, roads and
highways.
Operating at Excessive
Speeds
Operating the ATV at excessive speeds
increases the operator's risk of losing
control.
Always operate at a speed that's
appropriate for the terrain, the visibility and
operating conditions, and your experience.
14
SAFETY
Safety Warnings
Physical Control of the ATV
Removing a hand from the handlebars or
feet from the footrests during operation can
reduce your ability to control the vehicle or
cause loss of balance and ejection from the
ATV. If the operator's foot is not firmly
planted on the footrest, it could also contact
the rear wheels.
Never remove your hands from the
handlebars while operating, and always
keep both feet on the footrests.
Turning Improperly
Turning improperly could cause loss of
traction, loss of control, accident or overturn.
Always follow proper procedures for turning
as described in the owner's manual.
Never turn abruptly or at sharp angles. Never
turn at high speeds. Practice turning at slow
speeds before attempting to turn at faster
speeds.
Jumps and Stunts
Attempting wheelies, jumps and other
stunts increases the risk of an accident or
overturn.
Never attempt wheelies, jumps, or other
stunts. Avoid exhibition driving.
Improper Hill Climbing
Improper hill climbing could cause loss of
control or overturn. Always follow proper
procedures for climbing hills as described in
the owner's manual. See page 49.
15
SAFETY
Safety Warnings
Descending Hills Improperly
Improperly descending a hill could cause loss
of control or overturn.
• Always follow proper procedures for travel-
ing down hills as described in the owner's
manual. NOTE: A special technique is
required when braking while traveling down-
hill. See page 51.
• Always descend a hill with the transmission
in forward gear. Do not descend a hill with
the transmission in neutral.
• Always check the terrain carefully before
descending a hill.
• Shift your weight rearward.
• 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.
Crossing Hillsides
Driving on a sidehill is not recommended.
Improper procedure could cause loss of control
or overturn. Avoid crossing the side of any hill
unless absolutely necessary.
If crossing a hillside is unavoidable, always follow
proper procedures as described in the owner's
manual. See page 50.
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 52.
16
SAFETY
Safety Warnings
Stalling While Climbing a Hill
Stalling, rolling backwards or improperly
dismounting while climbing a hill could cause an
overturn.
• Always maintain a steady speed when climbing
a hill.
If all forward speed is lost:
• Keep body weight uphill.
• Apply the brakes.
• Lock the parking brake when fully stopped.
• 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 52.
If the ATV begins rolling downhill:
• Keep body weight uphill.
• Never apply engine power.
• Never apply the rear brake while rolling backwards. Apply the single-lever
brake gradually.
• When fully stopped, apply the 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 52.
Operating on Steep Hills
Operating on excessively steep hills could cause
an overturn.
Never operate on hills too steep for the ATV or for
your abilities. Never operate the ATV on hills
steeper than 25 degrees.
17
SAFETY
Safety Warnings
Operating on Slippery Terrain
Failure to use extra caution when operating on
excessively rough, slippery or loose terrain could
cause loss of traction, loss of control, accident or
overturn.
Do not operate on excessively rough, slippery or
loose terrain. Always use extra caution on rough,
slippery or loose terrain.
Operating in Unfamiliar Terrain
Failure to use extra caution when operating on
unfamiliar terrain could result in an accident or
overturn.
Unfamiliar terrain may contain hidden rocks,
bumps, or holes that could cause loss of control or
overturn.
Travel slowly and use extra caution when operating
on unfamiliar terrain. Always be alert to changing
terrain conditions.
18
SAFETY
Safety Warnings
Operating Improperly in Reverse
Improperly operating in reverse could result in a collision with an obstacle or
person. Always follow proper operating procedures as outlined in this manual.
See page 55.
Before shifting into reverse gear, always check for obstacles or people behind
the ATV. When it's safe to proceed, back slowly.
Improper Tire Maintenance
Operating this ATV with improper tires
or with improper or uneven tire
pressure could cause loss of control or
accident.
Always use the size and type of tires
specified for your ATV.
Always maintain proper tire pressure as
described in the owner's manual and
on safety labels.
Operating Over Obstacles
Improperly operating over obstacles could cause loss of control or overturn.
Before operating in a new area, check for obstacles. Avoid operating over large
obstacles such as rocks and fallen trees. If unavoidable, use extreme caution
and always follow proper operating procedures as outlined in this manual. See
page 54.
Skidding or Sliding
Skidding or sliding can cause loss of control or overturn (if tires regain traction
unexpectedly).
On slippery surfaces such as ice or loose gravel, travel slowly and use extra
caution to reduce the chance of skidding or sliding. Do not operate on
excessively slippery surfaces.
19
SAFETY
Safety Warnings
Operating Through Deep Water
Operating the ATV through deep or fast-
flowing water could cause the tires to float,
causing loss of control or overturn.
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
53):
• Travel slowly.
• Balance your weight carefully.
• Avoid sudden movements.
• Maintain a slow and steady forward motion. Do not make sudden turns or
stops, and do not make sudden throttle changes.
• Wet brakes may have reduced stopping ability. After leaving water, test the
brakes. Apply them lightly several times while driving slowly. The friction will
help dry out the pads.
Improper Cargo Loading
Overloading the ATV or carrying/towing cargo improperly may cause changes in
handling, which could cause loss of control or an accident.
• 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 dis-
tance for braking.
• NEVER exceed 50 MPH (80 km/h) when rear cargo loads are above 75 lbs.
(34 kg) and/or front cargo loads are above 37 lbs. (17 kg).
• Always follow the instructions in the owner's manual for carrying cargo or pull-
ing a trailer. See page 57.
20
SAFETY
Safety Warnings
Operating on Frozen Bodies of Water
Operating on frozen bodies of water may result in serious injury or death if the
ATV and/or the operator fall through the ice.
Never operate the ATV on a frozen body of water unless you have indepen-
dently verified that the ice is sufficiently thick to support the weight and moving
force of the ATV, you and your cargo, together with any other vehicles in your
party. Variances in snow depth and/or water currents may result in uneven ice
thickness. Always check with local authorities and residents to confirm ice condi-
tions and thickness over your entire route. ATV operators assume all risk associ-
ated with ice conditions on frozen bodies of water.
Poor Visibility
Operating the ATV in darkness or inclement weather could result in a collision or
accident, especially if operating on a road or street. This ATV is not equipped
with highway-approved lights. Operate this vehicle off-road only. Use caution
and drive at reduced speeds in conditions of reduced visibility such as fog, rain
and darkness. Clean headlights frequently and replace burned out headlamps
promptly.
Operating a Damaged ATV
Operating a damaged ATV can result in an accident. After any overturn or
accident, have a qualified service dealer inspect the entire machine for possible
damage, including (but not limited to) brakes, throttle and steering systems.
Physical Skills
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.
Hot Exhaust Systems
Exhaust system components are very hot during and after use of the vehicle.
Hot components can cause burns and fire. Do not touch hot exhaust system
components. Always keep combustible materials away from the exhaust
system. Use caution when traveling through tall grass, especially dry grass.
Unauthorized Use of the ATV
Leaving the keys in the ignition can lead to unauthorized use of the vehicle,
which could result in an accident or overturn. Always remove the ignition key
when the vehicle is not in use.
21
SAFETY
Safety Decals and Locations
Warning labels have been placed on the vehicle for your protection.
Read and follow the instructions on each label carefully. If any of the
labels shown in this manual differ from the labels on your vehicle,
always read and follow the instructions of the labels on the vehicle.
If an informational or graphic label becomes illegible or comes off, con-
tact your POLARIS dealer to purchase a replacement. Replacement
safety labels are provided by POLARIS at no charge. The part number is
printed on the label.
General Warning
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:
• without proper training or instruction
• at speeds too fast for your skills or the conditions
• on public roads - a collision can occur with another vehicle
• with a passenger - passengers affect balance and steering and increase risk
of losing control
ALWAYS:
• use proper riding techniques to avoid vehicle overturns on hills and rough
terrain and in turns
• avoid paved surfaces - pavement may seriously affect handling and control
LOCATE AND READ OWNER’S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
7175376
22
SAFETY
Safety Decals and Locations
Discretionary Warning
WARNING
• Never operate this ATV on HILLS
steeper than 25 degrees 25q.
To prevent overturn on hilly terrain,
use throttle and brakes gradually,
and shift weight uphill.
• REVERSE operation can be
dangerous even at low speeds.
Steering becomes difficult. To
prevent loss of control, avoid
sudden braking or sharp turns.
7175511
Tire Pressure/Load Warning
WARNING
Improper tire pressure or overloading can cause loss of control.
Loss of control can result in severe injury or death.
• Cold tire pressure:
Front: 5.0 psi (34.5 kPa)
Rear: 5.0 psi (34.5 kPa)
• Maximum weight capacity: 485 lbs. (220 kg)
7175642
Hitch Capacity Label
TRAILER MAX WEIGHT: 1225 LBS. (557 KG) ON LEVEL GROUND
HITCH MAX. VERTICAL WEIGHT: 120 LBS. (55 KG)
7174159
“No Passenger” Warning
WARNING
NEVER ride as a passenger.
Passengers can cause a loss of control, resulting in SEVERE INJURY or
DEATH.
7175378
Age 16 Warning
WARNING
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.
7175374
Discretionary
Warning
+
23
SAFETY
Safety Decals and Locations
Clutch Cover Warning
WARNING
• Moving parts hazard under belt-clutch guard. To prevent serious injury, do not
operate vehicle with guard removed.
• Do not modify engine or clutch. Doing so can cause part failure, possible
imbalance, and excessive engine RPM, which can result in serious injury or
death.
NO STEP
7172563
Rack Warning, Front and Rear
WARNING
• DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may
result causing severe injury or death. Tow only from tow hooks or hitch.
• Max Rack Loads: Front 90 lbs. (41 kg) Rear 180 lbs. (82 kg)
7172572
Override Warning
WARNING
Improper use of override button can lead to loss of control resulting in serious
injury or death. Do not activate override while throttle is engaged. Always apply
throttle gradually while in reverse.
7175486
+
+
Tire Pressure/Load
Warning
General
Warning
+
“No Passenger”
Warning
Age 16
Warning
+
Rack
Warning
+
Rack
Warning
+
Clutch Cover
Warning
Hitch
Capacity
24
FEATURES AND CONTROLS
Switches
Mode/Reverse Override Switch
This vehicle is equipped with a reverse speed limiter system. To gain
additional wheel speed while backing, release the throttle and depress
the override button.
WARNING! Pressing the override button while the throttle is open can cause
loss of control, which may result in serious injury or death. Always release the
throttle before pressing the override button.
Engine Stop Switch
Move the stop switch either left or right to
the OFF position to stop the engine quickly.
The engine will not start or run when the
switch is off.
Both the main switch and the engine stop switch will shut off all electri-
cal power to the vehicle, including lights.
Main Key Switch
Use the main key switch to start the engine. See page 44 for starting pro-
cedures.
Headlight Switch
Use the headlight switch to turn the lights on and off and to change the
lights from high beam to low beam. The key must be in the ON position
and the engine stop switch must be in the RUN position to operate the
headlights.
Mode/Reverse
Override
Switch
Main Key Switch
Engine
Stop Switch
Headlight
Switch
Choke
OFF OFFRUN
25
FEATURES AND CONTROLS
Throttle Lever
Operating an ATV with sticking or improperly operating throttle controls could
cause an accident. Never start or operate an ATV that has a sticking or
improperly operating throttle. Always contact your dealer for service before
operating the vehicle.
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.
Modifications to the electronic throttle control could result in failure to perform as
designed, which could result in an accident. Do not attempt to modify the throttle
control system or replace it with any after market throttle mechanisms. Always
ensure that the throttle cable is installed and properly routed to the throttle
control.
Engine speed and vehicle move-
ment are controlled by pressing the
throttle lever. The throttle lever is
spring loaded. Engine speed returns
to idle when the lever is released.
This ATV is equipped with
POLARIS Electronic Throttle Con-
trol (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.
WARNING
26
FEATURES AND CONTROLS
Brake Lever
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. Always contact your dealer for service before operating the vehicle.
Squeeze the brake lever toward the
handlebar to apply the front and
rear brakes. These 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.
WARNING
27
FEATURES AND CONTROLS
Master Cylinder/Brake Fluid
An over-full master cylinder may cause brake drag or brake lock-up, which could
result in an accident. Maintain brake fluid at the recommended level. Do not
overfill.
Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic,
meaning it rapidly absorbs moisture from the air. The moisture causes the
boiling temperature of the brake fluid to drop, which can lead to early brake fade
and the possibility of brake failure, which could result in an accident. After
opening a bottle of brake fluid, always discard any unused portion.
Check the brake fluid in the master
cylinder before each ride.
1. Position the ATV on a level
surface.
2. Position the handlebars so the
master cylinder is level.
3. View the brake fluid level
through the indicator window
on the top of the master cylin-
der. The eye will appear dark
when the fluid level is full.
When fluid is low, the eye will be clear.
4. If the fluid level is low add DOT 4 brake fluid only. Do not overfill.
WARNING
Master Cylinder
Indicator
Window
28
FEATURES AND CONTROLS
Parking Brake
Locking the Parking Brake
1. Place the transmission in
PARK.
2. Squeeze and release the brake
lever two or three times, then
squeeze and hold.
3. Push the parking brake lock
forward to engage the lock.
4. Release the brake lever.
5. To release the parking brake lock, squeeze and release the brake
lever. It will return to its unlocked position.
WARNING! Operating the ATV while the parking brake is engaged could result
in an accident or fire. Always check to be sure the parking brake is disengaged
before operating.
The parking brake may relax if left on for a long period of time. Always
block the wheels to prevent rolling. Always block the wheels on the
downhill side of the ATV if leaving it parked on a hill. Another option is
to park the ATV in a sidehill position. Never depend on the parking
brake alone if the ATV is parked on a hill. Always block the wheels to
prevent rolling.
29
FEATURES AND CONTROLS
Auxiliary Foot Brake
Never back down a hill. Applying the auxiliary brake when backing down a hill
may cause rear tipover, which could result in serious injury or death.
Use caution when applying the auxiliary brake. Do not aggressively apply the
auxiliary brake when going forward. The rear wheels may skid and slide
sideways, causing loss of control and serious injury or death.
The auxiliary brake system is intended to be used as a backup for the
main brake system. Should the main system fail, use the auxiliary foot
brake. Since this is a rear brake only, it will not be as effective as the all-
wheel single lever system.
The auxiliary foot brake is located
on the inside of the right footrest.
Operate this brake with your right
foot.
If the rear wheels slide while
using the auxiliary brake, reduce
brake pedal pressure to brake the
rear wheels without skidding.
Brake Fluid Level
Check the brake fluid level fre-
quently for the auxiliary brake
system. The reservoir is located
under the seat on the left side of
the vehicle. Maintain the fluid
level between the maximum and
minimum marks.
WARNING
Auxiliary Foot Brake
Foot Brake Fluid
Reservoir
30
FEATURES AND CONTROLS
Fuel Valve
The fuel valve is located in the left
front wheel well.
OFF: For vehicle storage and when
transporting.
ON: For normal operation.
Choke
The choke assists in starting a cold
engine. Refer to the engine starting
procedure on page 44 for correct
choke and throttle settings during
starting.
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 fil-
ter.
Fuel Tank Cap
This vehicle is equipped with a digital fuel gauge that will indicate a low
fuel condition. Refuel when the gauge indicates a low fuel condition.
Always refuel with the engine stopped, and outdoors or in a well venti-
lated area. Refuel on a level surface.
Remove the fuel tank cap to add fuel to the fuel tank. Use either leaded
or unleaded gasoline with a minimum pump octane number of 87=(R+
M/2) octane. Do not use fuel with ethanol content greater than 10 per-
cent, such as E-85 fuel.
OFF
ON
Fuel
Tank
Cap
Fuel
Valve
31
FEATURES AND CONTROLS
Automatic Transmission Gear Selector
The transmission gear selector is
located on the right side of the
vehicle.
H: High Gear
L: Low Gear
N: Neutral
R: Reverse
P: Park
To shift gears, brake to a com-
plete stop. When the engine is
idling, move the lever to the
desired gear.
NOTICE: Shifting gears with the engine speed above idle or while the vehicle is
moving could cause transmission damage.
Whenever the ATV is left unattended, always place the transmission in
PARK and lock the parking brake.
Belt Life
To extend belt life, use low forward gear when pulling a heavy load at
less than seven miles per hour for extended periods and when operating
uphill at a slow speed.
Gear
Selector
32
FEATURES AND CONTROLS
Instrument Cluster
Your ATV is equipped with an instrument cluster that senses vehicle
speed from the right front wheel. In addition to showing vehicle speed,
the speedometer needle flashes when a warning condition exists.
The instrument cluster measures distance in miles as well as hours of
operation. It also includes a reverse speed limiter function that limits the
ATV's speed to approximately 7-9 mph (11-14 km/h). Refer to page 24
for additional information.
NOTICE: High water pressure may damage ATV components. Wash the ATV
by hand or with a garden hose using mild soap.
Certain products, including insect repellents and chemicals, will
damage the speedometer lens and other plastic surfaces. Do not use
alcohol to clean the instrument cluster. Do not allow insect sprays to
contact the lens. Immediately clean off any gasoline that splashes on
the instrument cluster.
Rider
Information
Center
Speedometer
Needle
Speedometer
33
FEATURES AND CONTROLS
Instrument Cluster
Rider Information Center
The rider information center is located in the instrument cluster. All seg-
ments will light up for 2.5 seconds at start-up. If the instrument cluster
fails to illuminate, a battery over-voltage may have occurred and the
instrument cluster may have shut off to protect the electronic speedome-
ter. If this occurs, take the ATV to your POLARIS dealer for proper
diagnosis.
1. Gear Indicator - This
indicator displays gear
shifter position:
H = High Gear
L = Low Gear
N = Neutral
R = Reverse Gear
P = Park
2. Engine Hour Display
Indicator
3. Service Interval/Diag-
nostic Mode Indicator
4. Low Battery and Over Voltage - This warning usually indicates
that the ATV is operating at an RPM too low to keep the battery
charged. It may also occur when the engine is at idle and high elec-
trical load (lights, cooling fan, accessories) is applied. Drive at a
higher RPM or recharge the battery to clear the warning.
5. Odometer/Tachometer/Tripmeter/ Hour Meter
6. Fuel Gauge - The segments of the fuel gauge show the level of fuel
in the fuel tank. When the last segment clears, a low fuel warning is
activated. All segments will flash, FUEL will display in the LCD,
and the speedometer needle will blink. Refuel immediately.
7. Check Engine Warning Indicator - The word HOT displays if the
engine overheats. Do not operate the ATV if this warning appears.
Serious engine damage could result.
8. Mode Indicator
1
234
5
6
8
7
34
FEATURES AND CONTROLS
Instrument Cluster
Rider Information Center
Standard Modes
Use the MODE button to toggle through the mode options. The reverse
override button is also the MODE button. See page 24. The transmission
cannot be in reverse when using this feature.
Odometer Mode
The odometer records the miles traveled by the ATV.
Trip Meter Mode
The trip meter records the miles traveled by the ATV on each trip if it's
reset before each trip. To reset the trip meter, select the trip meter mode.
Press and hold the mode button (override button) until the total changes
to 0. In the Rider Information Center, the trip meter display contains a
decimal point, but the odometer displays without a decimal point.
Hour Meter Mode
This mode logs the total hours the engine has been in operation.
Tachometer Mode
The engine RPM is displayed digitally. Small fluctuations in the RPM
from day to day may be normal because of changes in humidity, temper-
ature and elevation.
35
FEATURES AND CONTROLS
Instrument Cluster
Rider Information Center
Diagnostic Mode
The wrench icon will display when the gauge is in the diagnostic mode.
To exit the diagnostic mode, turn the key switch off and on. Any move-
ment of the tires will also cause the gauge to exit the diagnostic mode.
To enter the diagnostics mode:
1. Turn the key switch off and wait 10 seconds.
2. Lock the parking brake.
3. Place the transmission in neutral.
4. Hold the mode/reverse override button and turn the key switch on.
Release the switch as soon as the display is activated.
5. Use the mode button to toggle through the diagnostic screens.
36
FEATURES AND CONTROLS
Instrument Cluster
Rider Information Center
Diagnostic Mode
Battery Voltage Screen
View this screen to check battery voltage level.
Tachometer Screen
View the tachometer to check engine speed.
Gear Circuit Diagnostic Screen
This screen displays the resistance value (in ohms) being read at the
gear switch input of the gauge. This screen is for informational purposes
only. Please see your dealer for all major repairs.
Programmable service interval
When the hours of engine operation equal the programmed service
interval setting, the wrench icon will flash for 5 seconds each time the
engine is started. When this feature is enabled, it provides a convenient
reminder to perform routine maintenance. See page 37.
The service interval is programmed at 50 hours at the factory.
37
FEATURES AND CONTROLS
Instrument Cluster
Rider Information Center
Diagnostic Mode
Programmable service interval
To enable or disable the service interval:
1. Enter the diagnostic mode.
2. Toggle to the service interval screen.
3. Press and hold the mode button for about 7 seconds, until either ON
or OFF appears in the Rider Information Center, depending on your
preference.
To reset the service interval:
1. Enter the diagnostic mode.
2. Toggle to the service interval screen.
3. Press and hold the mode button for 2-3 seconds, until the wrench
icon flashes. Release the button.
4. Press and release the mode button once to advance the setting by
one hour. Press and hold the mode button to advance the hours
quickly.
5. If you scroll past the intended number, press and hold the button
until the hours cycle back to zero.
6. When the desired setting is displayed, wait until the wrench icon
stops flashing. The new service interval is now programmed.
38
FEATURES AND CONTROLS
Instrument Cluster
Rider Information Center
Diagnostic Mode
Miles/Kilometers toggle
The display in the tripmeter and odometer can be changed to display
either standard or metric units of measurement.
1. Enter the diagnostic mode.
2. Toggle to the screen that displays either kilometers (KM) or miles
(MP).
3. Press and hold the mode button until the letters flash, then press and
release the button once. When the display stops flashing, the mode
has been set.
39
OPERATION
Failure to operate the ATV properly can result in a collision, loss of control,
accident or overturn, which may result in serious injury or death. Read and
understand all safety warnings outlined in the safety section of this owner’s
manual.
Break-In Period
The break-in period for your new POLARIS ATV is the first ten hours
of operation, or the time it takes to use the first two full tanks of gaso-
line. No single action on your part is as important as following the pro-
cedures for a proper break-in. Careful treatment of a new engine and
drive components will result in more efficient performance and longer
life for these components.
NOTICE: Excessive heat build-up during the first three hours of operation will
damage close-fitted engine parts and drive components. Do not
operate at full throttle or high speeds during the first three hours of
use.
WARNING
40
OPERATION
Break-In Period
Engine and Drivetrain Break-in
1. Fill the fuel tank with gasoline. See page 30. Always exercise
extreme caution whenever handling gasoline.
2. Check the oil level on the dipstick. See page 67. Add oil if neces-
sary to maintain the level between the safe and add marks.
3. Drive slowly at first. Select an open area that allows room to famil-
iarize yourself with vehicle operation and handling.
4. Vary the throttle positions. Do not operate at sustained idle.
5. Perform regular checks on fluid levels, controls and areas outlined
on the daily pre-ride inspection checklist. See page 43.
6. Pull only light loads.
7. During the break-in period, change both the oil and the filter at 20
hours or one month.
PVT Break-in (Clutches/Belt)
A proper break-in of the clutches and drive belt will ensure a longer life
and better performance. Break in the clutches and belt by operating at
slower speeds during the break-in period as recommended. Pull only
light loads. Avoid aggressive acceleration and high speed operation dur-
ing the break-in period.
If a belt fails, always clean away all debris when replacing the belt.
41
OPERATION
Safe Operation Practices
1. Complete the recommended safety training before operating this
vehicle. See page 7.
2. Do not allow anyone under 16 years of age to operate this vehicle.
Do not allow anyone with cognitive or physical disabilities to oper-
ate this vehicle.
3. Never carry a passenger on this ATV.
4. Engine exhaust fumes are poisonous. Never start the engine or let it
run in an enclosed area.
5. Before operating, learn how to use the auxiliary brake for emer-
gency situations (if service brakes become inoperable).
6. Operate this vehicle off-road only. Never operate the vehicle on
pavement or on any public street, road or highway, including dirt
and gravel roads.
7. Use caution and drive at reduced speeds in conditions of reduced
visibility such as fog, rain and darkness. Clean headlights fre-
quently and replace burned out headlamps promptly.
8. Drive in a manner appropriate for your skills and operating condi-
tions. Never operate at excessive speeds. Never attempt wheelies,
jumps, or other stunts. Never remove your hands from the handle-
bars while operating, and always keep both feet on the footrests.
9. Never consume alcohol or drugs before or while operating an ATV.
10. Always use the size and type of tires specified for your vehicle.
Always maintain proper tire pressure.
11. Never operate a damaged ATV. After any overturn or accident, have
a qualified service dealer inspect the entire machine for possible
damage.
12. Never operate the ATV on a frozen body of water unless you have
independently verified that the ice is sufficiently thick to support the
weight and moving force of the ATV, you and your cargo, together
with any other vehicles in your party.
13. Do not touch hot exhaust system components. Always keep com-
bustible materials away from the exhaust system.
14. Always remove the ignition key when the vehicle is not in use to
prevent unauthorized use.
42
OPERATION
Know Your Riding Area/Tread Lightly
Familiarize yourself with all laws and regulations concerning the opera-
tion of this off-road vehicle in your area. Respect the environment in
which you ride. Find out where the designated riding areas are by con-
tacting your POLARIS dealer, a local riding club or local officials.
Help keep our trails open for recreational vehicle use. As an off-road
enthusiast, you represent the sport and can set a good example (or a poor
example) for others to follow. Tread lightly. Operate with respect for the
terrain, avoid littering, and always stay on the designated trails.
Trail Etiquette
Always practice good etiquette when riding. Allow a safe distance
between your vehicle and other vehicles operating in the same area.
Communicate to oncoming operators by signaling the number of vehi-
cles in your group. When stopping, move your vehicle to the edge of the
trail as far as possible to allow others to pass safely.
43
OPERATION
Pre-Ride Checklist
Failure to inspect and verify that the ATV is in safe operating condition
before operating increases the risk of an accident. Always inspect the
ATV before each use to make sure it's in safe operating condition.
Item Remarks Page
Brake system/lever travel Ensure proper operation 26
74
Brake fluid Ensure proper level 27
Auxiliary brake Ensure proper operation 29
Front suspension Inspect, lubricate if necessary 65
Rear suspension Inspect, lubricate if necessary 65
Steering Ensure free operation -
Tires Inspect condition and pressure 77
Wheels/fasteners Inspect, ensure fastener tightness 77
78
Frame nuts, bolts, fasteners Inspect, ensure tightness -
Fuel and oil Ensure proper levels 30
67
Coolant level (if applicable) Ensure proper level 72
73
Coolant hoses (if applicable) Inspect for leaks -
Throttle Ensure proper operation 25
101
Indicator lights/switches Ensure operation 24
Engine stop switch Ensure proper operation 24
Air filter, pre-filter Inspect, clean 79
Air box sediment tube Drain deposits whenever visible -
Headlamp Check operation, apply POLARIS
dielectric grease when lamp is
replaced
24
82
Brake light/taillight Check operation, apply POLARIS
dielectric grease when lamp is
replaced
85
Riding gear Wear approved helmet, goggles, and
protective clothing
8
44
OPERATION
Starting the Engine
1. Position the vehicle on a level surface outdoors or in a well-venti-
lated area.
2. Place the transmission in PARK.
3. Lock the parking brake.
Tip: The starter interlock will prevent the engine from starting if the transmission
is in gear and the brake is not engaged.
4. Turn the fuel valve on.
5. Sit on the vehicle.
6. Do not use the choke if starting a warm engine. Excessive use of the
choke can cause the spark plug to become wet fouled.
7. If the engine is cold, pull the
choke knob out until it stops.
Tip: The variable choke is fully on
when the knob is pulled com-
pletely out. The choke is off when
the knob is pushed completely in.
The choke can be adjusted gradu-
ally, depending on how much
choke is needed for starting. Be
sure the choke is off during opera-
tion, as excess fuel washing into
the engine oil will increase wear
on engine components.
8. If the knob doesn't stay where
positioned, increase the ten-
sion by rotating the tension
adjusting nut clockwise.
9. Move the engine stop switch to RUN.
10. Do not press the throttle while starting the engine.
Tension
Adjusting Nut
45
OPERATION
Starting the Engine
11. Turn the ignition key past the ON position to engage the starter.
Activate the starter for a maximum of five seconds, releasing the
key when the engine starts.
NOTICE: Operating the vehicle immediately after starting could cause engine
damage. Allow the engine to warm up for several minutes before
operating the vehicle.
12. If the engine does not start, return the key to the OFF position and
wait five seconds before attempting to start again. Activate the
starter for another five seconds if necessary. Repeat this procedure
until the engine starts.
Tip: If a warm engine has cooled to a point where it does not readily start, inter-
mittent use of the choke button (pulled half way out) may be necessary. If
the engine is over-choked when warm, depress the throttle lever fully while
cranking to aid in starting. 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.
13. If the engine slows or stops, position the choke knob half way in to
allow proper engine warm up. Vary the engine RPM slightly with
the throttle to aid in warm-up. When the engine idles smoothly,
push the choke completely in.
Cold Weather Operation
If the ATV is used year-round, check the oil level frequently. A rising oil
level could indicate the accumulation of contaminates such as water or
excess fuel in the bottom of the crankcase. Water in the bottom of the
crankcase can lead to engine damage and must be drained. Water accu-
mulation increases as outside temperature decreases.
See your POLARIS dealer for engine heater kits, which provide quicker
warm-ups and easier starting in colder weather.
46
OPERATION
Driving Procedures
1. Wear a helmet and eye protection. See page 8.
2. Sit upright with both feet on the footrests and both hands on the
handlebars.
3. Start the engine and allow it to warm up.
4. Shift the transmission into gear.
5. Check your surroundings and determine your path of travel.
6. Release the parking brake.
7. Slowly depress the throttle with your right thumb and begin driving.
8. Drive slowly. Practice maneuvering and using the throttle and
brakes on level surfaces.
47
OPERATION
Turning the Vehicle
Your ATV is equipped with
a solid rear axle, which
drives both rear wheels
equally at all times. This
means that the wheel on the
outside of the turn must
travel a greater distance
than the inside wheel when
turning and the inside tire
must slip traction slightly.
To turn, steer in the direc-
tion 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 tech-
nique should be used for turning in reverse.
Practice making turns at slow speeds before attempting to turn at faster
speeds.
WARNING! Turning improperly can result in vehicle overturn. Never turn
abruptly or at sharp angles. Never turn at high speeds.
48
OPERATION
Driving on Slippery Surfaces
Whenever riding on slippery surfaces such as wet trails or loose gravel,
or during freezing weather, follow these precautions:
1. Do not operate on excessively rough, slippery or loose terrain.
2. Slow down when entering slippery areas.
3. Maintain a high level of alertness, reading the trail and avoiding
quick, sharp turns, which can cause skids.
4. Never apply the brakes during a skid. Correct a skid by turning the
handlebars in the direction of the skid and shifting your body
weight forward.
Sideways
skid
Turn in direction
of skid
49
OPERATION
Driving Uphill
Braking and handling are greatly affected when operating in hilly ter-
rain. Improper procedure could cause loss of control or overturn. When-
ever traveling uphill, follow these precautions:
1. Drive straight uphill.
2. Avoid steep hills (25q maximum).
3. Always check the terrain carefully before ascending any hill.
4. Never climb hills with excessively slippery or loose surfaces.
5. Keep both feet on the footrests.
6. Shift your weight uphill.
7. Proceed at a steady rate of speed and throttle opening. Opening the
throttle suddenly could cause the ATV to flip over backwards.
8. Remain alert and be prepared to take emergency action. This may
include quick dismounting of the vehicle.
25q Maximum
50
OPERATION
Driving on a Sidehill (Sidehilling)
Driving on a sidehill is not recommended. Improper procedure could
cause loss of control or overturn. Avoid crossing the side of any hill
unless absolutely necessary.
If crossing a sidehill is unavoidable, follow these precautions:
1. Slow down.
2. Avoid crossing the side of a steep hill.
3. Shift body weight uphill.
4. Keep your feet on the footrests.
5. Steer slightly into the hill to maintain vehicle direction.
6. If the vehicle begins to tip, quickly turn the front wheel downhill, if
possible, or dismount on the uphill side immediately!
51
OPERATION
Driving Downhill
When driving downhill, follow these precautions:
1. Avoid steep hills (25q maximum).
2. Shift body weight uphill.
3. Drive straight downhill.
4. Slow down. Excessive speed when traveling downhill can cause
loss of control.
5. Squeeze the brake lever gradually. Applying the brakes too firmly
may cause the rear wheels to lock, which could result in loss of con-
trol.
52
OPERATION
Turning Around on a Hill (K-Turn)
If the vehicle stalls while climbing a hill, never back it down the hill!
Use the K-turn to turn around.
1. Stop and lock the parking brake while keeping body weight uphill.
2. Leave the transmission in forward and shut off the engine.
3. Dismount on the uphill side of the vehicle, or on the left if the vehi-
cle 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 point-
ing across the hill or slightly downward.
6. Lock the parking brake. Remount the vehicle from the uphill side,
keeping body weight uphill.
7. Start the engine with the transmission still in forward.
8. Release the parking brake and proceed slowly, controlling speed
with the brake lever, until the vehicle is on more level ground.
8 ft. (2.4 m)
53
OPERATION
Driving Through Water
Your ATV can operate through
water with a maximum recom-
mended depth equal to the bot-
tom of the footrests. Follow
these procedures when operat-
ing through water:
1. Determine water depths and
current before entering
water.
2. Choose a crossing where
both banks have gradual
inclines.
3. Avoid operating through
deep or fast-flowing water.
NOTICE: Major engine damage can result if the vehicle is not thoroughly
inspected after operation in water. Perform the services outlined in
the maintenance chart. See page 60. The following areas need
special attention: engine oil, transmission oil, rear gearcase oil, and
all grease fittings
.
If the vehicle tips or overturns in water, or if the engine stops during or
after operating in water, restarting can result in serious engine
damage. Transport the vehicle to your dealer for service before
restarting the engine. If this is not possible, follow the vehicle
immersion inspection and drying procedures outlined on page 88,
then see your dealer for service at the first opportunity.
4. After leaving water, test the brakes. Apply them lightly several
times while driving slowly. The friction will help dry out the pads.
If it’s unavoidable to enter water deeper than the footrest level:
• Proceed slowly. Avoid rocks and obstacles.
• Balance your weight carefully. Avoid sudden movements.
• Maintain a steady rate of speed. Do not make sudden turns or stops.
Do not make sudden throttle changes.
Maximum
Depth
54
OPERATION
Driving Over Obstacles
Follow these precautions when operating over obstacles:
1. Always check for obstacles before operating in a new area.
2. Look ahead and learn to read the terrain. Be constantly alert for haz-
ards such as logs, rocks and low hanging branches.
3. Travel slowly and use extra caution when operating on unfamiliar
terrain. Not all obstacles are immediately visible.
4. Never attempt to operate over large obstacles, such as rocks or
fallen trees.
55
OPERATION
Driving in Reverse
Follow these precautions when operating in reverse:
1. Always check for obstacles or people behind the vehicle.
2. Always avoid backing downhill.
3. Back slowly.
4. Apply the brakes lightly for stopping.
5. Avoid turning at sharp angles.
6. Never open the throttle suddenly.
7. Do not use the override button unless additional wheel speed is
required for vehicle movement. Use the override with caution as
rearward vehicle speed is greatly increased. Do not operate at wide
open throttle. Operate the throttle just enough to maintain a desired
speed.
NOTICE: 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.
56
OPERATION
Hauling Cargo
Overloading the vehicle or carrying or towing cargo improperly can alter vehicle
handling and may cause loss of control or brake instability, which can result in
serious injury or death. Always follow these precautions when hauling cargo:
REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING
WHEN HAULING CARGO.
NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle. When
determining the weight you are adding to the vehicle, include the weight of the
operator, accessories, loads in the rack or box and the load on the trailer tongue.
The combined weight of these items must not exceed the maximum weight
capacity.
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 driving conditions. Carrying loads on only one rack
increases the possibility of vehicle overturn.
CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE. Carrying loads high
on the racks raises the center of gravity of the vehicle and creates a less stable
operating condition.
SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create
unstable operating conditions, which could result in loss of control of the vehicle.
OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When
handling off-centered loads that cannot be centered, securely fasten the load
and operate with extra caution. Always attach the tow load to the hitch point
designated for your vehicle.
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.
USE EXTREME CAUTION when operating with loads that extend over the rack
sides. Stability and maneuverability may be adversely affected, causing the
vehicle to overturn.
DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the
front rack.
DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS.
NEVER exceed 50 MPH (80 km/h) when rear cargo loads are above 75 lbs. (34
kg) and/or front cargo loads are above 37 lbs. (17 kg).
Vehicle should never exceed 10 mph (16 kph) while towing a load on a level
surface. Vehicle speed should never exceed 5 mph (8 kph) when towing loads in
rough terrain, while cornering, or while ascending or descending a hill.
WARNING
57
OPERATION
Hauling Cargo
Never exceed the weight capaci-
ties specified for your ATV on
warning labels and in the speci-
fications section of this manual.
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.
NEVER exceed 50 MPH (80
km/h) when rear cargo loads are
above 75 lbs. (34 kg) and/or
front cargo loads are above 37
lbs. (17 kg).
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.
Use low forward gear when hauling or towing heavy cargo to extend
belt life.
Towing Loads
Always attach a towed load to the hitch point. Remove the hitch from
the ATV when not towing a trailer. If towing a load, reduce rear rack
cargo weight by the amount of tongue weight.
• The combination of rear rack cargo weight and tongue weight must
not exceed the rear rack capacity.
• The total load (operator, accessories, cargo and weight on hitch) must
not exceed the maximum weight capacity of the vehicle.
NOTICE: Using an improper hitch or exceeding
the maximum tongue weight capacity
can result in serious damage to the
vehicle and will void your ATV
warranty. Never install a hitch longer
than 4" (10 cm). Never install
automotive accessories on your
POLARIS ATV. Always install
POLARIS-approved (or equivalent)
accessories designed for ATV use.
1/3
2/3
Maximum
4" (10 cm)
58
OPERATION
Parking on an Incline
Avoid parking on an incline if possible. If it's unavoidable, follow these
precautions:
1. Stop the engine.
2. Place the transmission in PARK.
3. Lock the parking brake.
4. Always block the rear wheels on the downhill side.
5. Turn the fuel valve off.
59
EMISSION CONTROL SYSTEMS
Noise Emission Control System
Do not modify the engine, intake or exhaust components, as doing so
may affect compliance with governmental noise level requirements.
Exhaust Emission Control System
The emissions from the exhaust of this vehicle are controlled by engine
design, including factory-set fuel delivery and ignition. The engine and
related components must be maintained at POLARIS specifications to
achieve optimal performance.
Engine idle speed is the only adjustment POLARIS recommends that
the operator perform. Any other adjustments should be performed by an
authorized POLARIS dealer.
Electromagnetic Interference
This spark ignition system complies with Canadian ICES-002.
This vehicle complies with the EMC requirements of European direc-
tives 97/24/EC and 2004/108/EC.
Non-ionizing Radiation: This vehicle emits some electromagnetic
energy. People with active or non-active implantable medical devices
(such as heart monitoring or controlling devices) should review the lim-
itations of their device and the applicable electromagnetic standards and
directives that apply to this vehicle.
60
MAINTENANCE
Periodic Maintenance Chart
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 chart.
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.
Record maintenance and service in the Maintenance Log beginning on
page 119.
Service and adjustments are important for proper vehicle operation. If
you're not familiar with safe service and adjustment procedures, have a
qualified dealer perform these operations.
Maintenance intervals in the following chart are based upon average rid-
ing conditions and an average vehicle speed of approximately 10 miles
per hour. Vehicles subjected to severe use must be inspected and ser-
viced more frequently.
Severe Use Definition
• Frequent immersion in mud, water or sand
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold
weather can indicate contaminants collecting in the oil sump or crank-
case. Change oil immediately if the oil level begins to rise. Monitor the
oil level, and if it continues to rise, discontinue use and determine the
cause or see your dealer.
61
MAINTENANCE
Periodic Maintenance Chart
Improperly performing the procedures marked with a could result in
component failure and cause an accident, which may result in serious injury or
death. Always have an authorized POLARIS dealer perform these services.
Maintenance Chart Key
X
Perform these operations more often for vehicles subjected to
severe use.
E Emission-related service (Failure to conduct this maintenance will
not void the emissions warranty but may affect emissions.)
Q
Have an authorized POLARIS dealer perform these services.
WARNING
62
MAINTENANCE
Periodic Maintenance Chart
Perform all services at whichever maintenance interval is reached first.
X Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service
Q Have an authorized POLARIS dealer perform these services.
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
Q
Steering - Pre-Ride - Make adjustments as need
ed. See Pre-Ride Checklist
on page 43.
X Front suspension - Pre-Ride -
X Rear suspension - Pre-Ride -
Tires - Pre-Ride -
X Brake fluid level - Pre-Ride -
X Brake lever travel - Pre-Ride -
Brake system - Pre-Ride -
Wheels/fasteners - Pre-Ride -
Frame fasteners - Pre-Ride -
X Engine oil level - Pre-Ride -
X
E
Air filter, pre-filter - Daily - Inspect; clean often; replace
as needed
X Air box sediment
tube
- Daily - Drain deposits when visible
Coolant - Daily - Check level daily, change
coolant every 2 years
Headlight/taillight/
worklight
- Daily - Check operation; apply
dielectric grease if replacing
lamps
X
E
Air filter,
main element
- Weekly - Inspect; replace as needed
Recoil housing - Weekly - Drain water as needed,
check often if operating in wet
conditions
X
Q
Brake pad wear 10 H Monthly 100 (160) Inspect periodically
Battery 20 H Monthly 200 (320) Check terminals; clean; test
X Demand drive fluid
(if equipped)
25 H Monthly 250 (400) Inspect level; change yearly
X Rear gearcase oil
(if equipped)
25 H Monthly 250 (400) Inspect level; change yearly
X Transmission oil 25 H Monthly 250 (400) Inspect level; change yearly
X
E
Engine breather
filter (if equipped)
25 H Monthly 250 (400) Inspect; clean if needed
63
MAINTENANCE
Periodic Maintenance Chart
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
X General
lubrication
50 H 3 M 500 (800) Lubricate all fittings, pivots,
cables, etc.
Carburetor float
bowl
50 H 6 M 500 (800) Drain bowl periodically and
prior to storage
Q
E
Throttle Cable/
ETC Switch
50 H 6 M 500 (800) Inspect; adjust; lubricate;
replace if necessary
Q
E
Choke cable 50 H 6 M 500 (800) Inspect; adjust; lubricate;
replace if necessary
E Carburetor air
intake ducts/flange
50 H 6 M 500 (800) Inspect duct for proper seal-
ing/air leaks
Drive belt 50 H 6 M 500 (800) Inspect; adjust; replace as
needed
Cooling system 50 H 6 M 1000 (1600) Inspect coolant strength
seasonally; pressure test
system yearly
X Engine oil change 100 H 6 M 1000 (1600) Perform a break-in oil change
at one month
X Oil filter change 100 H 6 M 1000 (1600) Replace with oil change
Q
E
Valve clearance 100 H 12 M 1000 (1600) Inspect; adjust
Q
E
Fuel system/filter 100 H 12 M 1000 (1600) Check for leaks at tank cap,
lines, fuel valve, filter, pump,
carburetor; replace lines
every two years
X Radiator
(if applicable)
100 H 12 M 1000 (1600) Inspect; clean external
surfaces
X Cooling hoses
(if applicable)
100 H 12 M 1000 (1600) Inspect for leaks
X Engine mounts 100 H 12 M 1000 (1600) Inspect
Exhaust muffler/
pipe
100 H 12 M 1000 (1600) Inspect
Q
E
Spark plug 100 H 12 M 1000 (1600) Inspect; replace as needed
Q
E
Ignition timing 100 H 12 M 1000 (1600) Inspect
X Wiring 100 H 12 M 1000 (1600) Inspect for wear, routing,
security; apply dielectric
grease to connectors
subjected to water, mud, etc.
64
MAINTENANCE
Periodic Maintenance Chart
X Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service
Q Have an authorized POLARIS dealer perform these services.
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
Q
Clutches (drive
and driven)
100 H 12 M 1000 (1600) Inspect; clean; replace worn
parts
Q
Front wheel
bearings
100 H 12 M 1000 (1600) Inspect; replace as needed
Q
Brake fluid 200 H 24 M 2000 (3200) Change every two years
Spark arrester 300 H 36 M 3000 (4800) Clean out
Idle speed - Adjust as needed
Q
Toe adjustment - Inspect periodically; adjust
when parts are replaced
Headlight aim - Adjust as needed
65
MAINTENANCE
Lubrication Guide
Check and lubricate all components at the intervals outlined in the Peri-
odic Maintenance Chart beginning on page 60. Items not listed in the
chart should be lubricated at the General Lubrication interval.
The a-arms and lower control arms are lubricated at the factory, and no
additional lubrication will be needed. However, if these components are
subjected to severe use, grease zerks have been provided for additional
lubrication at the user's discretion.
Item Lube Capacity at
Fluid Change
Inspection Procedure
Engine Oil PS-4 PLUS
Performance
Synthetic 2W-50
2 qt. (1.9 l) Maintain level in safe range
on dipstick. See page 67.
Brake Fluid DOT 4 Only --- Maintain level between fill
lines. See page 27.
Transmission Oil AGL PLUS
Transmission
Fluid
33.8 oz. (1000 ml) Maintain level at bottom of fill
hole threads. See page 70.
66
MAINTENANCE
Engine Oil
Oil Recommendations
Always change the oil filter whenever changing oil.
POLARIS recommends the use of POLARIS PS-4 PLUS Performance
Synthetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may
need to be changed more frequently if POLARIS oil is not used. Always
use 2W-50 oil. Follow the manufacturer's recommendations for ambient
temperature operation. See page 113 for the part numbers of POLARIS
products.
NOTICE: Mixing brands or using a non-recommended oil may cause serious
engine damage. Always use the recommended oil. Never substitute
or mix oil brands.
Lubricant Capacity Drain Plug Torque
PS-4 PLUS Performance
Synthetic 2W-50 4-Cycle Oil
2 qts. (1.9 l) 14-17 ft. lbs. (19-23 Nm)
67
MAINTENANCE
Engine Oil
Oil Level
Access the oil dipstick and fill tube
from the left side of the ATV.
A rising oil level between checks in
cool weather driving can indicate
contaminants such as gas or mois-
ture collecting in the crankcase. If
the oil level is over the full/safe
mark, change the oil immediately.
1. Position the vehicle on a level
surface.
2. Start the engine. Allow it to idle
for 20-30 seconds. Stop the
engine.
3. Remove the dipstick. Wipe it
dry with a clean cloth.
4. Reinstall the dipstick com-
pletely.
5. Remove the dipstick and check
the oil level. Maintain the oil
level in the safe range. Do not
overfill.
Dipstick
Safe
Add Oil
{
Safe Range
68
MAINTENANCE
Oil and Filter Change
Always change the oil and filter at the intervals outlined in the Periodic
Maintenance Chart beginning on page 60. Always change the oil filter
whenever changing oil.
1. Position the vehicle on a level surface.
2. Start the engine. Allow it to idle for two to three minutes.
3. Stop the engine.
4. Clean the area around the drain
plug.
5. Place a drain pan under the oil
tank.
6. Remove the drain plug. Allow
the oil to drain completely.
CAUTION! Hot oil can cause burns to
skin. Do not allow hot oil to contact skin.
7. Install a new sealing washer on
the drain plug. The sealing sur-
faces on drain plug and crank-
case should be clean and free of
burrs, nicks or scratches.
8. Reinstall the drain plug. Torque
to 14-17 ft. lbs. (19-23 Nm).
9. Disconnect the lower oil deliv-
ery hose and remove the screen
fitting from the oil tank. Clean
the fitting. The fitting threads must be sealed with LOCTITE PST
505 or PTFE seal tape.
10. Reinstall the screen fitting and rotate the fitting clockwise a mini-
mum of 2 1/2 turns into the tank threads. Continue to rotate the fit-
ting until the nipple of the fitting aligns with the mark on the tank.
Do not over-tighten. Maximum torque for the screen fitting is 25 ft.
lbs. (34 Nm).
11. Reattach the oil line.
Drain
Plug
Screen
Fitting
New Sealing Washer
Alignment Mark
69
MAINTENANCE
Oil and Filter Change
12. Place shop towels beneath the oil
filter. Using an oil filter wrench,
turn the filter counter-clockwise
to remove it.
13. Using a clean dry cloth, clean the
filter sealing surface on the crank-
case.
14. Lubricate the o-ring on the new
filter with a film of fresh engine
oil. Check to make sure the o-ring
is in good condition.
15. Install the new filter and rotate it clockwise by hand until the filter
gasket contacts the sealing surface, then turn it an additional 1/2
turn.
16. Approximately one cup of engine oil will remain in the crankcase.
To drain, remove the drain plug on the lower right side of the crank-
case. The sealing surfaces on the drain plug and crankcase should
be clean and free of burrs, nicks or scratches.
17. Reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm).
18. Remove the dipstick.
19. Add two quarts (1.9 l) of recommended oil. Reinstall the dipstick.
Tip: If the sump is not drained, add about 1 3/4 quarts (1.6 l) initially.
20. Place the transmission in PARK.
21. Lock the parking brake.
22. Prime the oil pump using the procedure on page 70. Then stop
the engine and inspect for leaks.
23. Check the oil level. Add oil as needed to bring the level to the upper
mark on the dipstick.
24. Dispose of used filter and oil properly.
70
MAINTENANCE
Oil and Filter Change
Oil Pump Priming
This priming procedure must be per-
formed whenever the oil hose connection
between the oil tank and pump inlet has
been disconnected.
1. Clamp or pinch off the vent line
approximately 2" (5 cm) from the oil
tank, between the end of the oil tank
vent fitting and the vent line's pres-
sure relief slit.
2. Start the engine. Allow it to idle for
10-20 seconds.
3. Remove the vent line clamp. If the line is bled properly, you should
hear a rush of air, indicating that the line is properly primed and
ready for operation.
Tip: If you do not hear air, the line has not bled. Repeat the priming procedure.
Transmission Oil
Always check and change the transmission oil at the intervals outlined
in the Periodic Maintenance Chart beginning on page 60. Maintain the
oil level at the bottom of the fill plug hole threads. See page 113 for the
part numbers of POLARIS products.
The fill plug is located on the left side of the ATV, under the rear fender,
behind the wheel. The drain plug is located on the right side of the
gearcase, on the right side of the ATV, behind the wheel well.
Clamp
Pressure
Relief Slit
Tank
2"
(5 cm)
Drain Plug
Fill Plug
71
MAINTENANCE
Transmission Oil
Transmission Oil Recommendations
Oil Check
1. Position the vehicle on a level
surface.
2. Remove the fill plug. Check the
oil level.
3. Add the recommended fluid as
needed to bring the level to the
bottom of the fill hole threads.
4. Reinstall the fill plug. Torque to
specification.
Oil Change
1. Remove the fill plug.
2. Place a drain pan under the gearcase. Remove the drain plug. Allow
the oil to drain completely.
3. Clean and reinstall the drain plug. Torque to specification.
4. Add the proper amount of the recommended oil.
5. Reinstall the fill plug. Torque to specification.
6. Check for leaks.
7. Dispose of used oil properly.
Lubricant Capacity Fill Plug
Torque
Drain Plug
Torque
AGL PLUS Transmission Fluid 33.8 oz.
(1000 ml)
20-25 ft. lbs.
(27-34 Nm)
20-25 ft. lbs.
(27-34 Nm)
Fill
Level
Fill Plug
72
MAINTENANCE
Cooling System
The engine coolant level is controlled, or maintained, by the recovery
system. The recovery system components are the recovery bottle, the
radiator filler neck, the radiator pressure cap and the connecting hose.
As coolant operating temperature increases, the expanding (heated)
excess coolant is forced out of the engine, past the pressure cap, and into
the recovery bottle. As engine coolant temperature decreases the con-
tracting (cooled) coolant is drawn back up from the bottle, past the pres-
sure cap, and into the radiator.
Some coolant level drop on new vehicles is normal as the system is
purging itself of trapped air. Check the coolant level and maintain as
recommended by adding coolant to the recovery bottle.
POLARIS recommends the use of POLARIS Premium 60/40 anti-
freeze/coolant or a 50/50 mixture of high quality aluminum compatible
anti-freeze/coolant and distilled water. POLARIS Premium 60/40 is
already premixed and ready to use. Do not dilute with water. See page
113 for the part numbers of POLARIS products.
Always follow the manufacturer's mixing recommendations for the
freeze protection required in your area.
Recovery Bottle Coolant
The recovery bottle is located
on the left side of the vehicle.
1. Remove the left side panel.
See page 76.
2. Maintain the coolant level
between the minimum and
maximum marks on the
bottle (when the fluid is
cool).
3. Add coolant as needed.
Recovery
Bottle
73
MAINTENANCE
Cooling System
Radiator Coolant
To ensure that the coolant maintains its ability to protect the engine,
POLARIS recommends that you drain the system completely every two
years and add a fresh mixture of antifreeze and water.
Replace the coolant any time the cooling system has been drained for
maintenance or repair. If the recovery bottle has run dry, check the level
in the radiator. Add coolant as needed.
CAUTION! Escaping steam can cause burns. Never remove the pressure cap
while the engine is warm or hot. Always allow the engine to cool before
removing the pressure cap.
1. Open the front box cover.
2. Remove the access panel
screws. Squeeze the outer
edges of the panel inward to
remove the panel.
3. Remove the pressure cap.
4. Using a funnel, slowly add
coolant through the radiator
filler neck.
5. Reinstall the pressure cap.
Use of a non-standard pres-
sure cap will not allow the
recovery system to function
properly. Contact your dealer
for the correct replacement part.
6. Reinstall the access panel and secure the front box cover.
Radiator
Cap
74
MAINTENANCE
Brakes
Hand Brake
The front and rear brakes are hydraulic disc brakes, activated by moving
the single brake lever toward the handlebar. These brakes are self-
adjusting.
Under normal operation, the diaphragm extends into the reservoir as
fluid level drops. If the fluid level is low and the diaphragm is not
extended, a leak is likely and the diaphragm should be replaced. To
ensure proper diaphragm operation, always fill the reservoir as needed
whenever the cover is loosened or removed. Do not overfill.
WARNING! 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.
The following checks are recommended to keep the brake system in
good operating condition. Check more often if brakes are used heavily
under normal operation.
1. Always keep brake fluid at an adequate
level. See page 27.
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. Replace brake pads when
they are worn to 3/64" (1 mm).
5. Check the security and surface condition
of the disc.
Auxiliary Foot Brake
The hydraulic auxiliary brake system requires no adjustment. Check the
brake fluid level frequently for the auxiliary brake system. See page 29.
3/64" (1 mm)
75
MAINTENANCE
Toe Alignment
Use the following procedure to check the toe alignment of the vehicle.
The recommended toe alignment is 1/8" to 1/4" (3-6 mm) toe out.
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. Position the vehicle on a
level surface.
2. Place the handlebars in a
straight-ahead position.
3. Tie a length of string
between two stands as
shown in the illustration.
Position the stands so
that the string is flush
with the side of the rear
tire. If available, you
may use a long straight-
edge instead of string.
4. Measure the distance
from the string to the
rim at the front (1) and
rear (2) of the front rim.
The rear measurement
should be 1/16"-1/8" (2-3 mm) more than the front measurement on
each side of the vehicle to obtain the recommended 1/8" to 1/4" (3-6
mm) toe out alignment.
5. Repeat the measurement procedure on the other side of the vehicle.
6. If you discover improper alignment, see your POLARIS dealer for
service.
String
Stand
2
1
FRONT
76
MAINTENANCE
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.
Side Panel Removal
1. Remove the seat.
2. Grasp the rear of the side panel near the rear cab. With a firm
motion, pull the panel outward to disengage the side panel from the
grommet.
3. Pull the panel downward and rearward to remove it.
Footwell Removal
1. Remove the four screws on
the bottom of the footwell.
2. Use a flat screwdriver or
sidecutters to remove the
plastic rivets securing the
footwell to the fenders.
3. Remove the footwell.
Step 1 Step 2 Step 3
Screws
Rivets
77
MAINTENANCE
Tires
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. Always follow all tire maintenance
procedures as outlined in this manual and on the labels on the vehicle. Always
use original equipment size and type when replacing tires.
Refer to the specifications section beginning on page 114 for recom-
mended tire type, size and pressure.
Tire Tread Depth
Always replace tires
when tread depth is
worn to 1/8" (3 mm)
or less.
Front Wheel Hub Tightening
Front wheel bearing tightness and spindle nut retention are critical com-
ponent operations. All service must be performed by your authorized
POLARIS dealer.
Wheel Removal
1. Stop the engine.
2. Place the transmission in PARK.
3. Lock the parking brake.
4. Loosen the wheel nuts slightly.
WARNING! Do not service axle nuts that have a cotter pin installed. See your
POLARIS dealer.
5. Elevate the side of the vehicle by placing a suitable stand under the
footrest frame.
6. Remove the wheel nuts.
7. Remove the wheel.
WARNING
1/8" (3 mm)
78
MAINTENANCE
Tires
Wheel Installation
1. Place the transmission in PARK.
2. Lock the parking brake.
3. Place the wheel on the hub with the valve stem toward the outside
and rotation arrows on the tire pointing toward forward rotation.
4. Install the wheel nuts and finger-tighten them.
5. Lower the vehicle to the ground.
6. Torque the wheel nuts to specification.
WARNING! Loose nuts could cause a tire to come off during operation, which
could result in an accident or overturn. Always ensure that all nuts are torqued to
specification.
Wheel Nut Torque Specifications
Check the wheel nut torques occasionally and when they've been loos-
ened for maintenance service.
Nut Type Nut Torque
Lug Nut (Aluminum
Wheels)
30 ft. lbs. (41 Nm)
PLUS 1/4 TURN
2-Piece Flange Nut
(Steel Wheels)
27 ft. lbs. (37 Nm)
79
MAINTENANCE
Air Filter
1. Remove the seat.
2. Release the air box cover
clips, and remove the air box
cover.
3. Loosen the clamp and
remove the filter.
4. Remove the fabric type pre-
filter from the main filter.
Wash the pre-filter in soapy
water, then rinse and let dry.
5. Reinstall the pre-filter over
the main filter. Install a new
main filter if needed.
6. Reinstall the filter into the air
box and tighten the clamp.
Do not over-tighten the clamp, as filter damage could occur.
7. Reinstall the air box cover and the seat.
Main Filter
Pre-Filter
Breather
Filter
80
MAINTENANCE
Breather Filter/Hose
The breather filter is on the hose that runs between the engine and air
box. See illustration above.
1. Remove the left side panel. See page 76.
2. Remove the hose clamps from the filter and pull the filter out of the
hoses.
3. Inspect the filter for debris. Blow gently through the filter in the
direction of the arrow to check for clogging. Replace a damaged or
clogged filter.
4. Check the hoses for cracks, deterioration, abrasion, or leaks.
Replace as needed.
5. Reinstall the filter and hose clamps. The filter is effective with the
arrow pointing in either direction.
NOTICE: Operation of your vehicle without a breather filter can cause engine
damage. Always reinstall the breather filter after removing it for
service.
81
MAINTENANCE
Fuse Replacement
If the engine stops or will not
start, or if you experience other
electrical failures, a fuse may need
replacement. Locate and correct
any short circuits that may have
caused the blown fuse, then
replace the fuse. Spare fuses are
provided in the rear storage box.
1. Open the front box cover.
2. Remove the suspect fuse from
the fuse panel. If the fuse is
blown, install a new fuse with
the same amperage.
3. Secure the front box cover.
Fuse Panel
Fuses
5or61520 20
82
MAINTENANCE
Lights
Poor lighting can result in reduced visibility when driving. Headlight
and taillight lenses become dirty during normal operation. Clean lights
frequently and replace burned out lamps promptly. Always make sure
lights are adjusted properly for best visibility.
Headlight Lamp Replacement
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.
1. Remove the two screws on the lower front corners of the headlight
pod.
2. Remove the screw from the rear of the pod.
3. Lift the pod slightly while depressing the tabs at the rear of the pod.
4. Lift the pod cover and disconnect the speedometer harnesses from
the speedometer.
CAUTION! Hot components can cause burns to skin. Allow lamps to cool
before servicing.
5. Unplug the headlamp from the wiring harness. Be sure to pull on the
connector, not on the wiring.
6. Turn the lamp counter-clockwise to remove it.
7. Apply dielectric grease to the socket and install the new lamp. Make
sure the tab on the lamp locates properly in the housing.
8. Reassemble the pod.
83
MAINTENANCE
Lights
High Beam Adjustment
The headlight beam can be adjusted slightly upward or downward. Use
the following procedure to make the adjustment.
1. Position the vehicle on a level surface with the headlight approxi-
mately 25 ft. (7.6 m) from a wall. Place the transmission in PARK.
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.Turn the headlight switch to high beam.
4. Observe the headlight aim on the wall. The most intense part of the
headlight beam should be two inches (5 cm) below the mark on the
wall. Include rider weight on the seat when measuring.
5. The adjustment knob is located on the right side of the headlight
pod. Adjust the beam to the desired position by turning the knob
either clockwise or counter-clockwise.
Low Beam Adjustment
The low beam can be adjusted slightly
upward or downward.
1. Loosen the phillips screw located at the
rear of the headlamp.
2. Tilt the headlamp upward or down-
ward.
3. Tighten the screw.
25 ft.
(7.6 m)
2" (5 cm)
Phillips
Screw
84
MAINTENANCE
Lights
Headlight Housing Replacement
1. Remove the two screws on the lower front corners of the headlight
pod.
2. Lift the pod slightly while depressing the tabs at the rear of the pod.
3. Lift the pod cover and disconnect the speedometer harnesses from
the speedometer.
4. Unplug the headlamp from the wiring harness.
5. Use a small screwdriver to remove the o-rings from the headlight
mounting tabs.
6. Pull the headlight housing up to release it from the locking tabs.
7. Lift the adjusting knob up to remove it from the locking tabs.
8. Carefully pull the assembly up
and out of the pod.
9. Reverse the steps to install the
new housing and reassemble
the pod. The distance from the
headlamp parting line to the
end of the adjustment knob
stop is 5 1/8" (13 cm).
10. Adjust the headlight aim by
turning the adjusting knob.
5 1/8"
(13 cm)
85
MAINTENANCE
Lights
Lower Headlamp Replacement
1. Turn the back of the headlight
harness counter-clockwise and
pull the harness assembly away
from the headlight assembly.
2. Remove the headlamp and install
the new headlamp.
3. Reinstall the harness assembly
into the headlight assembly.
4. Turn the headlight harness clock-
wise to secure the headlamp.
Taillight/Brakelight Lamp Replacement
1. Remove the harness connector
from the back of the light
assembly.
2. Turn the lamp counter-clock-
wise to remove it.
3. Apply dielectric grease to the
socket and install the new
lamp.
4. Reinstall the harness connector.
5. Test the light for proper operation.
Harness
Connector
Lamp
86
MAINTENANCE
Spark Plugs
Spark Plug Recommendations
Refer to the specifications section beginning on page 114 for the recom-
mended spark plug type and gap for your vehicle. Torque spark plugs to
specification.
NOTICE: Using non-recommended spark plugs can result in serious engine
damage. Always use POLARIS-recommended spark plugs.
Spark Plug Inspection
Spark plug condition is indicative of engine operation. Check the spark
plug firing end condition after the engine has been warmed up and the
vehicle has been driven at higher speeds. Immediately check the spark
plug for correct color. See page 87.
CAUTION! A hot exhaust system and engine can cause burns. Wear
protective gloves when removing a spark plug for inspection.
1. Rotate the spark plug cap 1/4 turn and pull it off the spark plug.
2. Using the special wrench provided in the tool pouch, rotate the
spark plug counter-clockwise to remove it.
3. Reverse the procedure for spark plug installation. Torque to specifi-
cation.
Plug Condition Torque Specification
New Spark Plug 9-11 ft. lbs. (12-15 Nm)
Previously Installed Spark Plug 17-20 ft. lbs. (23-27 Nm)
87
MAINTENANCE
Spark Plugs
Spark Plug Inspection
Normal Spark Plug
The normal insulator tip is gray, tan or light brown. There will be few
combustion deposits. The electrodes are not burned or eroded. This indi-
cates the proper type and heat range for the engine and the service.
The tip should not be flaky and white. A white insulator tip indicates
overheating, caused by use of an improper spark plug or incorrect carbu-
retion adjustments.
Wet Fouled Spark Plug
The wet fouled insulator tip is black. A damp oil film covers the firing
end. There may be a carbon layer over the entire nose. Generally, the
electrodes are not worn. General causes of fouling are excessive oil, use
of non-recommended oil, improper use of the choke, or incorrect throt-
tle body/carburetor adjustments.
88
MAINTENANCE
Vehicle Immersion
If your vehicle becomes immersed, major engine damage can result if
the machine is not thoroughly inspected. Take the vehicle to your dealer
before starting the engine. If it's impossible to take your ATV to a dealer
before starting it, follow the steps outlined below.
1. Move the ATV to dry land or at the very least, to water below the
footrests.
2. Check the air box. If water is present, dry the air box and replace the
filter with a new filter.
3. Turn the fuel valve off.
4. Remove the spark plug.
5. Loosen the carburetor drain
screw.
6. Turn the engine over several
times using the electric start.
7. Dry the spark plug. Reinstall the
plug or install a new plug
8. Tighten the carburetor drain
screw.
9. Turn the fuel valve on.
10. Attempt to start the engine. If
necessary, repeat the drying pro-
cedure.
11. Take the ATV to your dealer for service as soon as possible, whether
you succeed in starting it or not.
12. If water has been ingested into the PVT, follow the procedure on
page 92 for drying out the PVT.
Drain Screw
89
MAINTENANCE
Spark Arrester
Failure to heed the following warnings while servicing the spark arrester could
result in serious injury or death. Never run the engine in an enclosed area.
Remove any combustible materials from the area. Wear eye protection and
leather work gloves. Do not stand behind or in front of the vehicle while purging.
Never go under the vehicle while it's inclined.
The exhaust system can get extremely hot. Do not perform service on the spark
arrester while the system is hot. Allow components to cool sufficiently before
proceeding.
Use the following procedure to periodically purge accumulated carbon
from the exhaust pipe/muffler.
1. Remove the arrester clean-out
plug from the bottom of the
muffler.
2. Place the transmission in
PARK.
3. Start the engine.
4. Quickly squeeze and release
the throttle lever several times
to purge carbon from the system.
5. If carbon comes out of the exhaust, cover or plug the exhaust outlet.
Wear protective gloves.
6. Lightly tap on the exhaust pipe with a rubber mallet while repeating
step 4.
7. If particles are still suspected to be in the muffler, elevate the rear of
the vehicle one foot (30 cm) higher than the front. Block the wheels.
8. Repeat steps 4 to 6 until no more particles are expelled.
9. Stop the engine. Allow the arrester to cool.
10. Reinstall the arrester plug and remove the exhaust outlet cover or
plug.
WARNING
Exhaust
Outlet
Clean-Out Plug
90
MAINTENANCE
PVT System
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. Always look for
and remove debris inside and around the clutch and vent system when
replacing the belt.
• 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.
WARNING
91
MAINTENANCE
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 fly-
weights 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.
On POLARIS ATVs, the approximate gear ratio difference between
high and low range is 1:2.25. This difference in gearing affects the oper-
ation of the PVT, especially at speeds less than 7 MPH (11 km/h), due to
the system's dependence on engine speed.
For example, when operating at a ground speed of 3 MPH (5 km/h) in
low range, the engine speed would be around 3000 RPM. This is well
above the engagement speed of 1200 - 1400 RPM. However, in high
range at 3 MPH (5 km/h), the engine would be running at only 1500
RPM. Whenever operating this close to the engagement speed, the
engine may be running at a speed too low to provide the pinch needed to
prevent belt slip. Belt slip is responsible for creating the excessive heat
that destroys belts, wears clutch components and causes outer clutch
covers to fail.
The air temperature in the clutch cover is substantially reduced by using
low range while operating at low ground speeds. Reducing the tempera-
ture inside the clutch cover greatly extends the life of the PVT compo-
nents (belt, cover, etc.).
92
MAINTENANCE
PVT System
When To Use Low Range and High Range
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 operat-
ing.
1. Position the vehicle on a level surface.
2. Remove the drain plug. Allow the water to drain completely. Rein-
stall the drain plug.
3. Start the engine. Place the transmission in PARK.
4. 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.
5. Allow the engine RPM to settle to idle speed, then shift the trans-
mission to the lowest available range.
6. Test for belt slippage. If the belt slips, repeat the process.
7. Take the vehicle to your dealer for service as soon as possible.
Condition Range to Use
Operating at speeds less than 7 MPH (11 km/h) Low
Towing heavy loads Low
Operating in rough terrain (swamps, mountains, etc.) Low
Operating at speeds greater than 7 MPH (11 km/h) High
93
MAINTENANCE
Battery
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.
Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can
result from contact with skin, eyes or clothing.
Antidote:
External: Flush with water.
Internal: Drink large quantities of water or milk. Follow with milk of magnesia,
beaten egg, or vegetable oil. Call physician immediately.
Eyes: Flush with water for 15 minutes and get prompt medical attention.
Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away.
Ventilate when charging or using in an enclosed space. Always shield eyes
when working near batteries. KEEP OUT OF REACH OF CHILDREN.
Your ATV may have either a sealed battery, which requires little mainte-
nance, or a conventional battery. A sealed battery can be identified by its
flat covers on the top of the battery. A conventional battery has six filler
caps on the top of the battery.
Always keep battery terminals and connections free of corrosion. If
cleaning is necessary, remove corrosion with a stiff wire brush. Wash
with a solution of one tablespoon baking soda and one cup water. Rinse
well with tap water and dry off with clean shop towels. Coat the termi-
nals with dielectric grease or petroleum jelly. Be careful not to allow
cleaning solution or tap water into a conventional battery.
WARNING
WARNING
94
MAINTENANCE
Battery
Battery Removal
1. Disconnect the battery hold-down strap.
2. Remove the battery cover (if equipped).
3. On conventional batteries, remove the battery vent tube.
4. Disconnect the black (negative) battery cable first.
5. Disconnect the red (positive) battery cable last.
6. Lift the battery out of the ATV. Be careful not to tip a conventional
battery sideways, which could spill electrolyte.
NOTICE: If electrolyte spills, immediately wash it off with a solution of one
tablespoon baking soda and one cup water to prevent damage to the
vehicle.
95
MAINTENANCE
Battery
Battery Installation
Using a new battery that has not been fully charged can damage the bat-
tery and result in a shorter life. It can also hinder vehicle performance.
Follow the battery charging instructions on page 97 before installing the
battery.
1. Ensure that the battery is fully charged.
2. Place the battery in the battery holder.
3. With conventional batteries, install the battery vent tube (sealed bat-
teries do not have a vent tube). The vent tube must be free of
obstructions and securely installed. Route the tube away from the
frame and vehicle body to prevent contact with electrolyte.
WARNING! Battery gases could accumulate in an improperly installed vent tube
and cause an explosion, resulting in serious injury or death. Always ensure that
the vent tube is free of obstructions and is securely installed as recommended.
4. On conventional batteries, coat the terminals with dielectric grease
or petroleum jelly.
5. Connect and tighten the red (positive) cable first.
6. Connect and tighten the black (negative) cable last.
7. Install the battery cover (if equipped).
8. Secure the battery hold-down strap.
9. Verify that cables are properly routed. Cables should be safely
tucked away at the front and rear of the battery.
96
MAINTENANCE
Battery
Battery Storage
Whenever the vehicle is not used for a period of three months or more,
remove the battery from the vehicle, ensure that it's fully charged, and
store it out of the sun in a cool, dry place. Check battery voltage each
month during storage and recharge as needed to maintain a full charge.
Tip: Power plug leads may need to be bent down so that the battery cover can
be installed.
POLARIS recommends maintaining battery charge by using a
POLARIS Battery Tender charger or by charging about once a month to
make up for normal self-discharge. Battery Tender can be left connected
during the storage period, and will automatically charge the battery if
the voltage drops below a pre-determined point. See page 113 for the
part numbers of POLARIS products.
Battery Fluid (Conventional Battery)
A poorly maintained battery will
deteriorate rapidly. Check the battery
fluid level often. Maintain the fluid
level between the upper and lower
level marks.
Add only distilled water. Tap water
contains minerals that are harmful to
a battery.
Lower
Mark
Upper
Mark
97
MAINTENANCE
Battery
Battery Charging (Conventional Battery)
1. Remove the battery from the vehicle to prevent damage from leak-
ing or spilled electrolyte during charging. See page 94.
2. Charge the battery with a charging output no larger than 1/10 of the
battery’s amp/hr rating. Charge as needed to raise the specific grav-
ity to 1.270 or greater.
3. Reinstall the battery. See page 95. Make sure the positive terminal is
toward the front of the vehicle.
Battery Charging (Sealed Battery)
The following battery charging instructions apply only to the installa-
tion of a sealed battery. Read all instructions before proceeding with the
installation of this battery.
The sealed battery is already filled with electrolyte and has been sealed
and fully charged at the factory. Never pry the sealing strip off or add
any other fluid to this battery.
The single most important thing about maintaining a sealed battery is to
keep it fully charged. Since the battery is sealed and the sealing strip
cannot be removed, you must use a voltmeter or multimeter to measure
DC voltage.
WARNING! An overheated battery may explode, causing severe injury or
death. Always watch charging times carefully. Stop charging if the battery
becomes very warm to the touch. Allow it to cool before resuming charging.
For a refresh charge, follow all instructions carefully.
1. Check the battery voltage with a voltmeter or multimeter. A fully
charged battery will register 12.8 V or higher.
2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps
or less until battery voltage is 12.8 or greater.
3. When using an automatic charger, refer to the charger manufac-
turer's instructions for recharging. When using a constant current
charger, use the guidelines on the next page for recharging.
98
MAINTENANCE
Battery
Battery Charging (Sealed Battery)
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
99
MAINTENANCE
Camber and Caster
The camber and caster are non-adjustable.
Rear Spring
The rear shock absorber spring is adjusted
by rotating the adjuster either clockwise
or counter-clockwise to increase or
decrease spring tension.
Accessory springs are available through
your POLARIS dealer.
Handlebars
The handlebars can be adjusted for rider
preference.
WARNING! Improper adjustment of the handlebars or incorrect torquing of the
adjuster block tightening bolts can cause limited steering or loosening of the
handlebars, resulting in loss of control and serious injury or death. Follow the
adjustment procedures exactly, or see your POLARIS dealer for service.
1. Remove the upper headlight
pod.
2. Loosen the four handlebar
bolts.
3. Adjust the handlebar to the
desired height.
4. 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.
5. 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" (3 mm) will
remain at the rear of the clamp
blocks.
Adjuster
Handlebar
Bolts
100
MAINTENANCE
Carburetor
Your POLARIS ATV is calibrated at the factory for optimal perfor-
mance at altitudes ranging from zero to 6,000 feet (1800 m) and temper-
atures 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 opera-
tion. Optional jets, available from your POLARIS dealer, are required
for operation above 6,000 feet and temperatures below +40 degrees F. (4
degrees C.)
Continuous operation of the engine without proper jetting when
required can cause poor performance, overheating or PVT or engine
damage. See your POLARIS dealer for more information about jetting
the ATV for conditions in your area.
Pilot screws are sealed with metal plugs and are serviceable only by
POLARIS dealers.
Carburetor/Engine Idle RPM Adjustment
Recommended engine idle RPM is 1200 +/- 200. If the engine idle
speed is unsatisfactory and all other conditions are favorable, the carbu-
retor can be adjusted.
1. Start the engine and allow it to
warm up for approximately five
minutes.
2. Place the transmission in gear.
3. Lock the parking brake.
4. Turn the screw in (clockwise) to
raise RPM. Turn the screw out
(counter-clockwise) to lower
RPM.
Idle Screw
101
MAINTENANCE
Throttle Cable Freeplay
Adjust throttle cable freeplay at the handlebar.
1. Locate the throttle cable
adjuster at the handlebar.
2. Squeeze the end of the rub-
ber boot and slide it far
enough to expose the end of
the inline cable adjuster.
3. Loosen the adjuster lock nut.
4. Rotate the boot to turn the
adjuster until 1/16" to 1/8"
(1.5-3 mm) of freeplay is
achieved at the thumb lever.
While adjusting freeplay, be
sure to flip the throttle lever
back and forth.
5. Tighten the lock nut.
6. Squeeze the end of the rub-
ber boot and slide it over the
cable adjuster to its original
position.
Lock Nut
Adjuster
Boot
102
MAINTENANCE
Cleaning and Storage
Washing the Vehicle
Keeping your POLARIS vehicle clean will not only improve its appear-
ance but it can also extend the life of various components.
NOTICE: High water pressure may damage components. POLARIS
recommends washing the vehicle by hand or with a garden hose,
using mild soap.
Certain products, including insect repellents and chemicals, will
damage plastic surfaces. Do not allow these types of products to
contact the vehicle.
The best and safest way to clean your POLARIS vehicle is with a gar-
den hose and a pail of mild soap and water.
1. Use a professional-type washing cloth, cleaning the upper body first
and the lower parts last.
2. Rinse with clean water frequently.
3. Dry surfaces with a chamois to prevent water spots.
Washing Tips
• Avoid the use of harsh cleaners, which can scratch the finish.
• Do not use a power washer to clean the vehicle.
• Do not use medium to heavy duty compounds on the finish.
• Always use clean cloths and pads for cleaning and polishing. Old or
reused cloths and pads may contain dirt particles that will scratch the
finish.
103
MAINTENANCE
Cleaning and Storage
Washing the Vehicle
If a high pressure water system is used for cleaning (not recommended),
exercise extreme caution. The water may damage components and could
remove paint and decals. Avoid directing the water stream at the follow-
ing items:
• Wheel bearings
• Radiator
• Transmission seals
•Brakes
• Cab and body panels
• Electrical components
• Switches and controls
• Labels and decals
If an informational or graphic label becomes illegible or comes off, con-
tact your POLARIS dealer to purchase a replacement. Replacement
safety labels are provided by POLARIS at no charge.
Grease all zerk fittings immediately after washing. Allow the engine to
run for a while to evaporate any water that may have entered the engine
or exhaust system.
Polishing the Vehicle
POLARIS recommends the use of common household aerosol furniture
polish for polishing the finish on your POLARIS vehicle. Follow the
instructions on the container.
Polishing Tips
• Avoid the use of automotive products, some of which can scratch the
finish of your vehicle.
• Always use clean cloths and pads for cleaning and polishing. Old or
reused cloths and pads may contain dirt particles that will scratch the
finish.
104
MAINTENANCE
Cleaning and Storage
Chrome Wheel Care (if equipped)
Proper maintenance will protect chrome wheels from corrosion, pre-
serve wheel life and ensure a “like new” appearance for many years.
Chrome wheels exposed to road salt (or salt in the air in coastal areas)
are more susceptible to corrosion if not properly cleaned. Clean chrome
wheels more often if they're exposed to salt or other corrosive elements.
1. Wash chrome wheels frequently. Use a mild detergent. Never use
abrasive cleaners on plated or painted surfaces.
2. Rinse well with clear water. Soap, detergents, salt, dirt, mud and
other elements can cause corrosion.
3. Polish the clean chrome wheels periodically. Use an automotive
grade chrome polish.
4. Routinely and liberally apply a weather resistant wax to each pol-
ished chrome wheel. Choose a product suitable for chrome finishes.
Read and follow the product labels and instructions.
Removing Corrosion
If light rust is found on the chrome finish, use steel wool (#0000-OTT
grade) to remove it. Gently rub the affected areas with the steel wool
until the corrosion has been removed. Clean and polish the wheel as out-
lined above.
105
MAINTENANCE
Cleaning and Storage
Storage Tips
NOTICE: Starting the engine during the storage period will disturb the
protective film created by fogging and damage could occur. Never
start the engine during the storage period.
Clean the Exterior
Make any necessary repairs and clean the vehicle as recommended. See
page 102.
Stabilize the Fuel
1. Fill the fuel tank.
2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel
Stabilizer. Follow the instructions on the container for the recom-
mended amount. Carbon Clean removes water from fuel systems,
stabilizes fuel and removes carbon deposits from pistons, rings,
valves and exhaust systems.
3. Allow the engine to run for 15-20 minutes to allow the stabilizer to
disperse through the fuel in the tank and carburetor.
4. Turn the fuel valve off.
5. Drain the carburetor bowl.
Oil and Filter
Change the oil and filter. See page 68.
Air Filter / Air Box
1. Inspect and clean (or replace) the pre-cleaner and air filter. See page
79.
2. Clean the air box.
3. Drain the sediment tube.
4. Clean or replace the breather filter. See page 80.
106
MAINTENANCE
Cleaning and Storage
Storage Tips
Fluid Levels
Inspect the fluid levels. Add or change fluids as recommended in the
Periodic Maintenance Chart beginning on page 60.
• Transmission
• Brake fluid (change every two years and any time the fluid looks dark
or contaminated)
• Coolant (test strength/fill)
Fog the Engine
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 two
ounces (59 ml) of engine oil into the cylinder.
3. Reinstall the spark plug. Torque to specification.
4. Apply dielectric grease to the inside of the spark plug cap. Reinstall
the cap.
5. Turn the engine over several times. Oil will be forced in and around
the piston rings and ring lands, coating the cylinder with a protec-
tive film of fresh oil.
6. Treat the fuel system with POLARIS Carbon Clean. See page 105.
7. If POLARIS fuel system additive is not used, the fuel tank, fuel
lines, and carburetor should be completely drained of gasoline.
8. To eliminate any fuel remaining in the carburetor, run the engine
until it stops.
107
MAINTENANCE
Cleaning and Storage
Storage Tips
Inspect and Lubricate
Inspect all cables and lubricate all areas of the vehicle as recommended
in the Periodic Maintenance Chart beginning on page 60.
Battery Storage
See pages 96-97 for storage and charging procedures.
Storage Area/Covers
Set the tire pressure and safely support the ATV with the tires slightly
off the ground. Be sure the storage area is well ventilated. Cover the
vehicle with a genuine POLARIS cover. Do not use plastic or coated
materials. They do not allow enough ventilation to prevent condensa-
tion, and may promote corrosion and oxidation.
Accessories
Auxiliary power outlets provide 12-volt power for operating accesso-
ries. Accessory outlets are available for all models. POLARIS also has a
wide range of additional accessories available for your ATV. Always
install accessories that are approved for ATV use. Please see your
POLARIS dealer.
108
MAINTENANCE
Transporting the ATV
Follow these procedures when
transporting the vehicle.
1. Stop the engine.
2. Place the transmission in
PARK.
3. Lock the parking brake.
4. Secure the fuel cap, oil cap
and seat.
5. Always tie the frame of the
ATV to the transporting
unit securely with suitable
straps or rope. Do not
attach tie straps to the front
A-arm bolt pockets, racks
or handlebars.
6. Remove the key to prevent
loss during transporting.
109
TROUBLESHOOTING
Drive Belt Wear/Burn
Possible Cause Solution
Driving onto a pickup or
tall trailer in high range
Use low range during loading.
Starting out going up a
steep incline
Use low range or turn around using the K-turn (see page
52).
Driving at low RPM or
ground speed (3-7 MPH)
Drive at a higher speed or use low range more frequently.
See page 92.
Insufficient warm-up at
low ambient tempera-
tures
Warm the engine at least 5 minutes. With the transmission
in neutral, advance the throttle to about 1/8 throttle in
short bursts, 5 to 7 times. The belt will become more flex-
ible and prevent belt burning.
Slow/easy clutch engage-
ment
Use the throttle quickly and effectively.
Towing/pushing at low
RPM/low ground speed
Use low range only.
Utility use/plowing Use low range only.
Stuck in mud or snow Shift the transmission to low range and carefully use fast,
aggressive throttle application to engage clutch.
WARNING! Excessive throttle may cause loss of control
and vehicle overturn.
Climbing over large
objects from a stopped
position
Shift the transmission to low range and 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. See page 92. Inspect clutch seals for
damage if repeated leaking occurs.
Clutch malfunction See your POLARIS dealer.
Poor engine performance Check for fouled plugs or foreign material in gas tank or
fuel lines. See your dealer.
Slippage from failure to
warm up belt
Always warm up the belt by operating below 30 mph for
one mile (5 miles or more when temperature is below
freezing).
Wrong or missing belt Install the recommended belt.
Improper break-in Always break in a new belt and/or clutch. See page 40.
110
TROUBLESHOOTING
Engine Doesn't Turn Over
Engine Turns Over, Fails to Start
Engine Backfires
Possible Cause Solution
Tripped circuit breaker or blown fuse Reset the breaker/Replace fuse
Low battery voltage Recharge the battery to 12.8 VDC
Loose battery connections Check all connections and tighten
Loose solenoid connections Check all connections and tighten
Possible Cause Solution
Out of fuel Refuel
Clogged fuel valve or filter Inspect and clean or replace
Water is present in fuel Drain the fuel system and refuel
Old or non-recommended fuel Replace with fresh recommended fuel
Fuel valve is turned off Turn the fuel valve on
Fouled or defective spark plug(s) Inspect plugs and replace if necessary
No spark to spark plug Inspect plugs, verify stop switch is on
Water or fuel in crankcase Immediately see your POLARIS dealer
Overuse of choke Inspect, clean and/or replace spark plugs
Low battery voltage Recharge the battery to 12.8 VDC
Mechanical failure See your dealer
Possible Cause Solution
Weak spark from spark plug Inspect, clean and/or replace spark plugs
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
Old or non-recommended fuel Replace with fresh recommended fuel
Incorrectly installed spark plug wires See your dealer
Incorrect ignition timing See your dealer
Mechanical failure See your dealer
Loose ignition connections Check all connections and tighten
Water present in fuel Replace with fresh recommended fuel
111
TROUBLESHOOTING
Engine Pings or Knocks
Engine Runs Irregularly, Stalls or Misfires
Possible Cause Solution
Poor quality or low octane fuel Replace with recommended fuel
Incorrect ignition timing See your dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
Possible Cause Solution
Fouled or defective spark plug(s) Inspect, clean and/or replace spark
plug(s)
Worn or defective spark plug wires See your dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
Loose ignition connections Check all connections and tighten
Water present in fuel Replace with new fuel
Low battery voltage Recharge battery to 12.8 VDC
Kinked or plugged fuel tank vent line Inspect and replace
Incorrect fuel Replace with recommended fuel
Clogged air filter Inspect and clean or replace
Reverse speed limiter malfunction See your dealer
Electronic throttle control malfunction See your dealer
Other mechanical failure See your dealer
Possible Lean Fuel Cause Solution
Low or contaminated fuel Add or change fuel, clean the fuel system
Kinked or plugged fuel tank vent line Inspect and replace
Low octane fuel Replace with recommended fuel
Clogged fuel filter Replace filter
Incorrect fuel Replace with recommended fuel
Incorrect jetting See your POLARIS dealer
Possible Rich Fuel Cause Solution
Fuel is very high octane Replace with lower octane fuel
Overuse of choke Inspect, clean and/or replace spark plugs
Stopping/starting without adequate
warm-up
Allow engine to warm up before operat-
ing and/or stopping
Incorrect fuel Replace with recommended fuel
Clogged air filter Inspect and clean or replace
Incorrect jetting See your POLARIS dealer
112
TROUBLESHOOTING
Engine Stops or Loses Power
Engine Overheating
Possible Cause Solution
Out of fuel Refuel, cycle key to ON position three
times for 5 seconds each, then start
Kinked or plugged fuel vent line Inspect and replace
Overuse of choke Inspect, clean and/or replace spark plugs
Water is present in fuel Replace with new fuel
Fouled or defective spark plug(s) Inspect, clean and/or replace spark
plug(s)
Worn or defective spark plug wires See your dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plug
Loose ignition connections Check all connections and tighten
Low battery voltage Recharge the battery to 12.8 VDC
Incorrect fuel Replace with fresh recommended fuel
Clogged air filter Inspect and clean or replace
Reverse speed limiter malfunction See your dealer
Electronic throttle control malfunction See your dealer
Other mechanical failure See your dealer
Overheated engine Clean radiator screen and core, clean
engine exterior, see your dealer
Possible Cause Solution
Debris lodged in screen Remove and clean the screen. Pull on the
top portion of the screen, then remove the
lower portion.
Plugged Radiator Use a garden hose to flush any debris
from the radiator fins. NOTE: High pres-
sure washers can deform the radiator fins
and reduce cooling efficiency.
Obstructed cooling fan Clean any debris or mud that may be
interfering with fan movement.
113
POLARIS PRODUCTS
Part
Number
Description
Engine Lubricant
2870791 Fogging Oil (12 oz. Aerosol)
2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt./.95 l)
2876245 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal./3.8 l)
Gearcase / Transmission Lubricants
2878068 AGL PLUS Transmission Fluid (qt./.95 l)
2878069 AGL PLUS Transmission Fluid (gal./3.8 l)
2870465 Pump for Gallon (3.8 l) Jug
Coolant
2871323 60/40 Coolant (gal./3.8 l)
2871534 60/40 Coolant (qt./.95 l)
Grease / Specialized Lubricants
2871312 Grease Gun Kit, Premium All Season
2871322 Premium All Season Grease (3 oz./89 ml cartridge)
2871423 Premium All Season Grease (14 oz./414 ml cartridge)
2871460 Starter Drive Grease
2871515 Premium U-Joint Lube (3 oz./89 ml cartridge)
2871551 Premium U-Joint Lube (14 oz./414 ml cartridge)
2871329
Dielectric Grease (Nyogel
TM
)
Additives / Miscellaneous
2871326 Carbon Clean Plus
2870652 Fuel Stabilizer
2872189 DOT 4 Brake Fluid
2871956
Loctite
TM
565 Thread Sealant
2859044
POLARIS Battery Tender
TM
Charger
114
SPECIFICATIONS
* Based on EU Directive 76/432/EC
HAWKEYE 400 2X4
Gross Vehicle Weight 1200 lbs. (544 kg)
Maximum Weight Capacity 485 lbs. (220 kg) (operator, cargo, accessories)
Dry Weight 635 lbs. (288 kg)
Fuel Capacity 4.25 gal. (16 l)
Engine Oil Capacity 2 qts. (1.9 l)
Transmission Oil Capacity 33.8 oz. (1000 ml) +/- 1.6 oz. (47 ml)
Coolant Capacity 2.7 qts. (2.5 l)
Front Rack/Box Capacity 90 lbs. (40.8 kg)
Rear Rack/Box Capacity 180 lbs. (81.6 kg)
Receiver Hitch Tongue
Capacity
120 lbs. (54 kg) (Rear rack capacity and tongue
weight not to exceed 180 lbs./81.6 kg)
Hitch Towing Rating 1225 lbs. (555.7 kg)
Unbraked Trailer Towing
Capacity*
1786 lbs. (810 kg)
Overall Length/Width/Height 83 in. (211 cm) / 48 in. (122 cm) / 48 in. (122 cm)
Wheelbase 50.75 in. (129 cm)
Ground Clearance 11 in. (28 cm)
Minimum Turning Radius 65 in. (165 cm) unloaded
Engine EH46PLE
Displacement 455 cc
Bore x Stroke 87.9x75mm
Alternator Output 260 w
Compression Ratio 10.1:1
Carburetor 34mm Mikuni
Pilot Jet 42.5
Main Jet 160
Needle Jet P-6M (829)
Jet Needle 4IB33-3
Pilot Screw By flow (taper 12.5q) (Brass Plug)
Ignition System Digital CDI
Ignition Timing 30q +/- 2q @ 5000 RPM
Spark Plug / Gap NGK BKR6E / .035 in. (0.9 mm)
Lubrication System Dry Sump
Driving System Type Automatic PVT (POLARIS Variable Transmission)
Front Suspension MacPherson strut with 8.2" (21 cm) travel
Rear Suspension Progressive rate with 9.5" (24 cm) travel
Shift Type Side Lever (H/L/N/R/P)
115
SPECIFICATIONS
Jetting Chart
Clutching Chart
HAWKEYE 400 2X4
Gear Reduction, Low 23.91:1
Gear Reduction, Reverse 21.74:1
Gear Reduction, Forward 10.57:1
Tires/Pressure, Front 25x8-12 / 5 psi (34.5 kPa)
Tires/Pressure, Rear 25x10-12 / 5 psi (34.5 kPa)
Brakes, Front/Rear Single-Control Hydraulic Disc
Brake, Auxiliary Foot-Activated Hydraulic Disc
Brake, Parking Hydraulic lock, all wheel
Headlight 1 Single Beam on Headlight Pod (50 watt)
2 Single Beam on Bumper (50 watt)
Taillights 8.26 watts
Brake Light 26.9 watts
Instrument Cluster LCD
ALTITUDE
Meters (Feet)
AMBIENT TEMPERATURE
Below 40q F
(Below 5q C)
+40qF and above
(+5qC and above)
0-1800 (0-6000) 167.5 160
1800-3700
(6000-12000)
155 150
Altitude Shift
Weight
Drive Clutch
Spring
Driven
Clutch
Spring
Helix and
Spring
Setting
Meters
(Feet)
0-1800
(0-6000)
10 WHF
PN 5632283
Blue/Green
PN 7041157
Black
PN 7041782
41-37q
PN 5132344
2+2
1800-3700
(6000-12000)
10 RH
PN 5630709
or 20-40
PN 5631356
Blue/Green
PN 7041157
Black
PN 7041782
41-37q
PN 5132344
2+2
116
WARRANTY
LIMITED WARRANTY
POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH
LIMITED WARRANTY on all components of the POLARIS vehicle against defects in
material or workmanship. This warranty covers the parts and labor charges for repair or
replacement of defective parts which are covered by this warranty. This warranty begins
on the date of purchase. The duration of this warranty may vary depending on location.
This warranty is transferable to another consumer during the warranty period through a
POLARIS dealer.
REGISTRATION
At the time of sale, the Warranty Registration Form must be completed by your dealer
and submitted to POLARIS within ten days. Upon receipt of this registration, POLARIS
will record the registration for warranty. No verification of registration will be sent to
the purchaser as the copy of the Warranty Registration Form will be the warranty entitle-
ment. 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 VEHICLE IS REGISTERED WITH POLARIS.
Initial dealer preparation and set-up of your vehcile is very important in ensuring trou-
ble-free operation. Purchasing a machine in the crate or without proper dealer set-up will
void your warranty coverage.
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 vehicle that
has been altered structurally, modified, neglected, improperly maintained, used for rac-
ing, or used for purposes other than for which it was manufactured, or for any damages
which occur during trailer transit or as a result of unauthorized service or the use of
unauthorized parts. In addition, this warranty does not cover physical damage to paint or
finish, stress cracks, tearing or puncturing of upholstery material, corrosion, or defects in
parts, components or the vehicle due to fire, explosions or any other cause beyond
POLARIS' control.
117
WARRANTY
WARRANTY COVERAGE AND EXCLUSIONS:
LIMITATIONS OF WARRANTIES AND REMEDIES
Warranty does not apply to parts exposed to friction surfaces, stresses, environmental
conditions and/or contamination for which they were not designed or not intended,
including but not limited to the following items:
Warranty applies to the product only and does not allow for coverage of personal loss.
Some items are considered “consumable,” meaning they are considered part of normal
maintenance or part of completing an effective repair. The following items are excluded
from warranty coverage in the event of a warranty claim:
This warranty also excludes failures resulting from improper lubrication; improper
engine timing; improper fuel; surface imperfections caused by external stress, heat, cold
or contamination; operator error or abuse; improper component alignment, tension,
adjustment or altitude compensation; failure due to snow, water, dirt or other foreign
substance ingestion/contamination; improper maintenance; modified components; use
of aftermarket components resulting in failure; unauthorized repairs; repairs made after
the warranty period expires or by an unauthorized repair center; use of the product in
competition or for commercial purposes. Warranty will not apply to any product which
has been damaged by abuse, accident, fire or any other casualty not determined a defect
of materials or workmanship.
• Wheels and tires • Finished and unfinished surfaces
• Suspension components • Carburetor/Throttle body components
• Brake components • Engine components
• Seat components • Drive belts
• Clutches and components • Hydraulic components
• Steering components • Circuit breakers/Fuses
• Batteries • Electronic components
• Light bulbs/Sealed beam lamps
• Spark Plugs • Lubricants such as oil, grease, etc.
• Filters • Batteries (unless defective)
• Fuel • Cosmetic damage/repair
• Sealants • Coolants
• Hotel fees • Meals
• Towing charges • Shipping/ handling fees
• Mileage • Product pick-up/delivery
• Rentals/Loss of product use • Loss of vacation/personal time
118
WARRANTY
WARRANTY COVERAGE AND EXCLUSIONS:
LIMITATIONS OF WARRANTIES AND REMEDIES
This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that
are not compatible with the vehicle. The exclusive remedy for breach of this warranty
shall be, at POLARIS' exclusive option, repair or replacement of any defective materi-
als, or components or products. THE REMEDIES SET FORTH IN THIS WARRANTY
ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF
THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON
FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY
DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR-
RANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR
OTHERWISE. THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND
SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY
FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PUR-
POSE. Some states do not permit the exclusion or limitation of incidental or consequen-
tial damages or implied warranties, so the above limitations or exclusions may not apply
to you if inconsistent with controlling state law.
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-
TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX
MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS
WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limi-
tations on how long an implied warranty lasts, so the above limitation may not apply to
you if inconsistent with controlling state law.
HOW TO OBTAIN WARRANTY SERVICE
If your vehicle requires warranty service, you must take it to a POLARIS dealer autho-
rized to repair POLARIS vehicles. When requesting warranty service you must present
your copy of the Warranty Registration form to the dealer. (THE COST OF TRANS-
PORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY).
POLARIS suggests that you use your original selling dealer; however, you may use any
POLARIS Servicing Dealer to perform warranty service.
Please work with your dealer to resolve any warranty issues. Should your dealer require
any additional assistance they will contact the appropriate personnel at POLARIS.
This warranty gives you specific legal rights, and you may also have other rights which
vary from state to state.
If any of the above terms are void because of state or federal law, all other warranty
terms will remain in effect.
119
MAINTENANCE LOG
Present this section of your manual to your dealer each time your vehicle is serviced.
This will provide you and future owners with an accurate log of maintenance and ser-
vices performed.
DATE MILES (KM)
OR HOURS
TECHNICIAN SERVICE PERFORMED / COMMENTS
120
MAINTENANCE LOG
DATE MILES (KM)
OR HOURS
TECHNICIAN SERVICE PERFORMED / COMMENTS
121
INDEX
A
Accessories . . . . . . . . . . . . . . . . . . . 107
Air Filter . . . . . . . . . . . . . . . . . . . . . . 79
Auxiliary Foot Brake . . . . . . . . . . . . 74
B
Battery . . . . . . . . . . . . . . . . . . . . 93-98
Charging (Conventional) . . . . . . . 97
Charging (Sealed) . . . . . . . . . 97-98
Fluid (Conventional) . . . . . . . . . . 96
Installation . . . . . . . . . . . . . . . . . . 95
Removal. . . . . . . . . . . . . . . . . . . . 94
Storage . . . . . . . . . . . . . . . . . . . . . 96
Belt Life . . . . . . . . . . . . . . . . . . . . . . 31
Boots. . . . . . . . . . . . . . . . . . . . . . . . . . 9
Brake Fluid, Auxiliary Foot Brake . . 29
Brake Fluid, Main Brake System . . . 27
Brake Lever. . . . . . . . . . . . . . . . . . . . 26
Brake, Foot . . . . . . . . . . . . . . . . . 29, 74
Brake, Hand Lever . . . . . . . . . . . . . . 74
Brake, Parking . . . . . . . . . . . . . . . . . 28
Brakelight Lamp Replacement . . . . . 85
Brakes . . . . . . . . . . . . . . . . . . . . . . . . 74
Break-In Period. . . . . . . . . . . . . . 39-40
Breather Filter. . . . . . . . . . . . . . . . . . 80
Breather Hose . . . . . . . . . . . . . . . . . . 80
C
Camber Adjustment . . . . . . . . . . . . . 99
Carburetor. . . . . . . . . . . . . . . . . . . . 100
Carburetor Adjustment . . . . . . . . . . 100
Cargo. . . . . . . . . . . . . . . . . . . . . . 56-57
Caster Adjustment. . . . . . . . . . . . . . . 99
Choke . . . . . . . . . . . . . . . . . . . . . . . . 30
Chrome Wheel Care . . . . . . . . . . . . 104
Cleaning and Storage . . . . . . . 102-107
Clothing . . . . . . . . . . . . . . . . . . . . . . . 9
Clutching Chart. . . . . . . . . . . . . . . . 115
Coolant Bottle. . . . . . . . . . . . . . . . . . 72
Coolant, Radiator . . . . . . . . . . . . . . . 73
Cooling System. . . . . . . . . . . . . . 72-73
Corrosion Removal, Chrome . . . . . 104
D
Drive Belt Wear/Burn. . . . . . . . . . . 109
Drivetrain Break-In. . . . . . . . . . . . . . 40
Driving Downhill . . . . . . . . . . . . . . . 51
Driving in Reverse . . . . . . . . . . . . . . 55
Driving on a Sidehill. . . . . . . . . . . . . 50
Driving on Slippery Surfaces . . . . . . 48
Driving Over Obstacles . . . . . . . . . . 54
Driving Procedures. . . . . . . . . . . . . . 46
Driving Through Water . . . . . . . . . . 53
Driving Uphill. . . . . . . . . . . . . . . . . . 49
E
Electromagnetic Interference . . . . . . 59
Engine Break-In . . . . . . . . . . . . . . . . 40
Engine Fogging. . . . . . . . . . . . . . . . 106
Engine Idle RPM Adjustment. . . . . 100
Engine Oil. . . . . . . . . . . . . . . . . . 66-67
Equipment Modifications . . . . . . . . . . 7
Etiquette, Trail Riding . . . . . . . . . . . 42
Exhaust Emission Control System . . 59
Eye Protection. . . . . . . . . . . . . . . . . . . 9
F
Fluid, Brake . . . . . . . . . . . . . . . . 27, 29
Foot Brake, Auxiliary. . . . . . . . . . . . 29
Footwell Removal. . . . . . . . . . . . . . . 76
Fuel Filter . . . . . . . . . . . . . . . . . . . . . 30
Fuel Recommendations . . . . . . . . . . 30
Fuel Safety . . . . . . . . . . . . . . . . . . . . 11
Fuel Tank Cap. . . . . . . . . . . . . . . . . . 30
Fuel Valve. . . . . . . . . . . . . . . . . . . . . 30
Fuse Replacement. . . . . . . . . . . . . . . 81
G
Gasoline Handling . . . . . . . . . . . . . . 11
Gear Selector . . . . . . . . . . . . . . . . . . 31
Gloves. . . . . . . . . . . . . . . . . . . . . . . . . 9
122
INDEX
H
Hand Brake . . . . . . . . . . . . . . . . . . . 74
Handlebar Adjustment. . . . . . . . . . . 99
Hauling Cargo . . . . . . . . . . . . . . . 56-57
Headlight Housing Replacement. . . 84
Headlight Lamp Replacement . . . . . 82
Headlight Switch . . . . . . . . . . . . . . . 24
Helmet . . . . . . . . . . . . . . . . . . . . . . . . 8
High Beam Adjustment. . . . . . . . . . 83
High Range Use. . . . . . . . . . . . . . . . 92
I
Idle RPM Adjustment . . . . . . . . . . 100
Immersion Maintenance . . . . . . . . . 88
Instrument Cluster . . . . . . . . . . . . 32-38
J
Jetting Chart. . . . . . . . . . . . . . . . . . 115
K
Key Switch. . . . . . . . . . . . . . . . . . . . 24
K-Turn . . . . . . . . . . . . . . . . . . . . . . . 52
L
Lights . . . . . . . . . . . . . . . . . . . . . 82-85
Headlight Housing Replacement 84
Headlight Lamp . . . . . . . . . . . . . 82
High Beam Adjustment . . . . . . . 83
Low Beam Adjustment. . . . . . . . 83
Lower Headlamp Replacement. . 85
Taillight/Brakelight. . . . . . . . . . . 85
Low Beam Adjustment . . . . . . . . . . 83
Low Range Use . . . . . . . . . . . . . . . . 92
Lower Headlamp Replacement . . . . 85
Lubrication Guide . . . . . . . . . . . . . . 65
M
Maintenance Chart. . . . . . . . . . . . 60-64
Master Cylinder . . . . . . . . . . . . . . . . 27
Mode Switch . . . . . . . . . . . . . . . . . . 24
Modifications. . . . . . . . . . . . . . . . . . . 7
N
Noise Emission Control System . . . . 59
O
Oil
Engine. . . . . . . . . . . . . . . . . . . 66-67
Transmission. . . . . . . . . . . . . . 70-71
Oil and Filter Change . . . . . . . . . 68-70
Oil Level, Engine. . . . . . . . . . . . . . . . 67
Oil Pump Priming . . . . . . . . . . . . . . . 70
Oil Recommendations . . . . . . . . . . . . 66
Override Switch. . . . . . . . . . . . . . . . . 24
P
Parking Brake . . . . . . . . . . . . . . . . . . 28
Parking on an Incline. . . . . . . . . . . . . 58
Periodic Maintenance Chart . . . . 60-64
Polaris Product List . . . . . . . . . . . . . 113
Polishing the Vehicle. . . . . . . . . . . . 103
Pre-Ride Checklist. . . . . . . . . . . . . . . 43
PVT Break-In . . . . . . . . . . . . . . . . . . 40
PVT Drying . . . . . . . . . . . . . . . . . . . . 92
PVT System. . . . . . . . . . . . . . . . . 90-92
R
Reverse Operation . . . . . . . . . . . . . . . 55
Reverse Override Switch. . . . . . . . . . 24
Rider Information Center. . . . . . . 33-38
Riding Area . . . . . . . . . . . . . . . . . . . . 42
Riding Gear . . . . . . . . . . . . . . . . . . . 8-9
S
Safe Operation Practices . . . . . . . . . . 41
Safety Decals. . . . . . . . . . . . . . . . . 2-23
Safety Labels
"No Passenger" Warning . . . . . . . 22
Age 16 Warning . . . . . . . . . . . . . . 22
Clutch Cover Warning . . . . . . . . . 23
Discretionary Warning . . . . . . . . . 22
General Warning. . . . . . . . . . . . . . 21
Override Warning . . . . . . . . . . . . . 23
Rack Warning, Front and Rear. . . 23
Tire Pressure/Load Warning. . . . . 22
123
INDEX
S
Safety Training . . . . . . . . . . . . . . . . . . 7
Safety Warnings . . . . . . . . . . . . . 10-20
Service Interval Programming . . . . . 37
Severe Use . . . . . . . . . . . . . . . . . . . . 60
Side Panel Removal . . . . . . . . . . . . . 76
Sidehilling. . . . . . . . . . . . . . . . . . . . . 50
Signal Words. . . . . . . . . . . . . . . . . . . . 4
Spark Arrester. . . . . . . . . . . . . . . . . . 89
Spark Plug Inspection. . . . . . . . . 86-87
Spark Plug Recommendations . . . . . 86
Spark Plug Torque Specification . . . 86
Spark Plugs . . . . . . . . . . . . . . . . . 86-87
Specifications . . . . . . . . . . . . . 114-115
Spring Adjustment, Rear Shock . . . . 99
Starting the Engine . . . . . . . . . . . 44-45
Steering Assembly . . . . . . . . . . . . . . 76
Storage . . . . . . . . . . . . . . . . . . 102-107
Storage Tips . . . . . . . . . . . . . . 105-107
Switches
Engine Stop Switch . . . . . . . . . . . 24
Headlight Switch . . . . . . . . . . . . . 24
Main Key Switch . . . . . . . . . . . . . 24
Mode/Reverse Override Switch. . 24
T
Taillight Lamp Replacement . . . . . . 85
Throttle Cable Freeplay . . . . . . . . . 101
Throttle Lever. . . . . . . . . . . . . . . . . . 25
Tire Tread Depth. . . . . . . . . . . . . . . . 77
T
Tires . . . . . . . . . . . . . . . . . . . . . . 77-78
Wheel Installation . . . . . . . . . . . . 78
Wheel Nut Torque . . . . . . . . . . . . 78
Wheel Removal . . . . . . . . . . . . . . 77
Toe Alignment . . . . . . . . . . . . . . . . . 75
Towing Loads. . . . . . . . . . . . . . . . . . 57
Trail Etiquette. . . . . . . . . . . . . . . . . . 42
Training. . . . . . . . . . . . . . . . . . . . . . . . 7
Transmission. . . . . . . . . . . . . . . . . . . 31
Transmission Oil. . . . . . . . . . . . . 70-71
Transmission Oil Recommendation . 71
Transporting the ATV. . . . . . . . . . . 108
Tread Lightly . . . . . . . . . . . . . . . . . . 42
Turning Around on a Hill . . . . . . . . . 52
Turning the Vehicle . . . . . . . . . . . . . 47
V
Vehicle Identification Numbers . . . . . 6
Vehicle Immersion . . . . . . . . . . . . . . 88
VIN. . . . . . . . . . . . . . . . . . . . . . . . . . . 6
W
Warning Symbols . . . . . . . . . . . . . . . . 4
Washing the Vehicle. . . . . . . . 102-103
Wheel Hub Tightening . . . . . . . . . . . 77
Wheel Installation. . . . . . . . . . . . . . . 78
Wheel Nut Torque Specifications. . . 78
Wheel Removal . . . . . . . . . . . . . . . . 77
For your nearest Polaris dealer,
call 1-800-POLARIS
or visit www.polarisindustries.com
Polaris Sales Inc.,
2100 Hwy. 55, Medina, MN 55340
Phone 1-888-704-5290
Part No. 9923552 Rev 01
Printed in USA
*9923552 *
WARNING
Improper vehicle use can result in SEVERE INJURY or DEATH.
NEVER operate:
S without proper training or instruction.
S at speeds too fast for your skills or the conditions.
S on public roads - a collision can occur with another
vehicle.
S with a passenger - passengers affect balance and
steering and increase risk of losing control.
ALWAYS:
S use proper riding techniques to avoid vehicle
overturns on hills and rough terrain and in turns.
S avoid paved surfaces - pavement may seriously affect
handling and control.
READ OWNER'S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
ALWAYS USE
AN APPROVED
HELMET AND
PROTECTIVE
GEAR
NEVER USE
ON PUBLIC
ROADS
NEVER CARRY
PASSENGERS
NEVER USE
WITH DRUGS
OR ALCOHOL
