Polaris 2000 Universal ATV User Manual

Part No. 9915299 Rev 05

PRINTED IN THE U.S.A.

2000

Universal

ATV

Read this manual carefully. It contains

important safety information. This is an

adult vehicle only. Operation is prohibited

for those under 16 years of age.

Owner’s Safety

and

Maintenance Manual

WARNING

The engine exhaust from this

product contains chemicals

known to cause cancer, birth de-

fects or other reproductive harm.

FOREWORD

Congratulations and thank you from Polaris Industries Inc. for purchasing one of

our all-terrain vehicles (ATV’s). Built with American engineering and manufactur-

ing know-how, it is designed to provide superior riding comfort, enjoyment and

safety.

This manual is furnished to ensure that theoperator isaware ofsafe operatingpro-

cedures. It also includes information about the general care and maintenance of

your ATV.

Carefully read the following pages. If you have any questions regarding this ATV

contact a Polaris dealer for assistance. Remember, Polaris dealers have the

knowledge and facilities to provide you with the best service possible.

PROTECT YOUR SPORT

Know all local, state/province riding laws;

Respect y our vehicle;

Respect the environment; and

You will gain the respect of others.

We also advise you to strictly follow the recommended maintenance program as

outlined. This preventive maintenance program is designed to ensure that all criti-

cal components on this ATV are thoroughly inspected at various intervals.

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

tions available at the time of printing. Polaris Industries Inc. reserves the right to

make product changes and improvements which may affect illustrations or ex-

planations.

No part of this manual shall be reproduced or used without the written permission

of Polaris Industries Inc.

Illustrations included in this manual are general representations of parts having a

similar function. Your model may differ.

AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An

ATV handles differently from other vehicles including motorcycles and

cars. A collision or rollover can occur quickly, even during routine maneu-

vers such as turning and driving on hills or over obstacles, if you fail to take

proper precautions.

SEVERE INJURY OR DEATH can result if you do not follow these instructions:

• Read this manual and all labels carefully and follow the operating procedures

described.

• Never operate an ATV without proper instruction. Take a training course. Be-

ginners shouldreceive training froma certifiedinstructor. Contactan authorized

Polaris ATV dealer or call Polaris at1-800-342-3764tofind outaboutthetraining

courses nearest you.

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

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

and all product labels, and has completed a c ertified training course.

• Always avoid operating an ATV on any paved surfaces, including sidewalks,

driveways, parking lots and streets.

• Never operate an ATV on any public street, road or highway, even a dirtor gravel

one.

• Neveroperate an ATV withoutwearing an approved helmetthatfitsproperly. You

should also wear eye protection (goggles or face shield), gloves, boots, long-

sleeved shirt or jacket, and long pants.

• Never consume alcohol or drugs before or while operating this ATV.

• Never operate at excessive speeds. Always travel at a speed which is proper

for the terrain, visibility and operating conditions, and your experience.

• Never attempt wheelies, jumps or other stunts.

• Always inspect y our ATV each time you use it to make sure it is in safe operating

condition. Always follow the inspection and maintenance procedures and

schedules described in this manual.

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

ATV during operation.

• Always go slowly and be extra careful when operating on unfamiliar terrain. Al-

ways be alert to c hanging terrain conditions when operating the ATV.

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

• Always follow proper procedures for turning as described in this manual. Prac-

tice turning at low speeds before attempting to turn at fasterspeeds. Do not turn

at excessive speed.

• Always have the ATV checked by an authorized Polaris dealer if it has been in-

volved in an accident.

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

on smaller hills before attempting larger hills.

• Always follow proper procedures for climbing hills as described in this manual.

Check the terrain carefully before you start up any hill. Never climb hills with ex-

cessively slippery or loose surfaces. Shift your weightforward. Never open the

throttle suddenly or make s udden gear changes. Never go over the top of any

hill at high speed.

• Always follow proper procedures for going down hills and for braking on hills as

described in this manual. Check the terrain carefully before you start down any

hill. Shift yourweightbackward. Never go down ahillathigh speed. Avoidgoing

down a hillatanangle which would cause the vehicle to lean sharplytooneside.

Go straight down the hill where possible.

• Always followproperprocedures forcrossingthe sideof a hill as described in this

manual. Avoid hills with excessively slippery or loose surfaces. Shift your

weight to the uphill side of the ATV. Never attempt to turn the ATV around on

any hill until you have mastered the turning technique described in this manual

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

• Always use proper procedures if you stall or roll backwards when climbing a hill.

To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll

backwards, follow the special procedure for braking described in this manual.

Dismount on the uphill side or to either side if pointed straight uphill. T urn the

ATV around and remount, following the procedure described in this manual.

• Always check for obstacles before operating in a new area. Never attempt to

operate over large obstacles, such as large rocks or fallen trees. Always follow

proper procedures when operating over obstacles as described in this manual.

• Always be careful of skidding or sliding. On slippery surfaces, such as ice, go

slowly and be very cautious in order to reduce the chance of skidding or sliding

out of control.

• Never operate an ATV in fast flowing water or in water deeper than that specified

in this manual. Remember that wet brakes may have reduced stopping ability.

Test your brakes after leaving water. If necessary, apply them lightly several

times to let friction dry out the pads.

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

in reverse. When it is safe to proceed in reverse, go slowly. Avoid turning at

sharp angles in reverse.

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

proper tire pressure as described in this manual.

• Never modify an ATV through improper installation or use of accessories.

• Never exceed the stated load capacityfor an ATV. Cargo shouldbe properly dis-

tributed and securely attached. Reduce speed and follow instructions in this

manual for carrying c argo or pulling a trailer. Allow greater distance for braking.

FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product

Safety Commission at 1-800 -638-2772, or Polaris at 1-800-342-3764.

indicates a potential hazard which

couldresult in serious injury ordeath.

WARNING

Additional Important Information...

Due to our concern for the safety of our customers and the general public, Polaris

hereby strongly recommends and requests that consumers not have installed on

a Polaris ATV any equipment which is intended to increase the speed or power of

thevehicle;ormakeany other modifications to the vehiclefor these purposes. Any

modifications to the original equipment of the ATV substantially increase the risk

of bodily injury. Please be aware thatthese modifications may create a substantial

safety hazard.

Polaris hereby informs you that the warranty on your ATV is terminated if any such

equipment has been added to the ATV or any modifications have been made to

the ATV which increase its speed or power.

We also advise you to strictly follow the recommended maintenance program out-

lined in this manual. This preventive maintenance program is designed to ensure

that all critical components on the ATV are thoroughly inspected by your dealer at

various mileage interv als.

NOTE:

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

tires, sprayers, or large racks may change the handling characteristics of the ATV.

Be certain any accessories added to this ATV have been approved by Polaris.

Familiarize yourself with their function and affect on the ATV.

The Polaris Preferred

Registered Owners

(PRO) Family

Your Owners Program

As the owner of a new Polaris vehicle, you are entitled to a FREE two- year mem-

bership in the Polaris PRO Family---the Preferred Registered Owners Family. It’s

an owners program for Polaris owners like you, people who have chosen the finest

recreational vehicle available, people who sharean interestin Polaris and its prod-

ucts.

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

membership packet that will include:

A letter of welcome to the PRO Family

A PRO Family card with your name and membership number

A colorful sticker of the PRO logo

A PRO merchandise brochure and order form.

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

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

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

telephone number is: 1-800-473-0111

The chance to arrange travel through the Polaris Travel Center. The toll-free

travel telephone number is: 1-800-267-1915

The chance to apply to serve on PRO Consumer Councils that provide input

into the Polaris vehicles of the future

The chance to serve as a PRO Field Evaluator and provide feedback on your

new vehicle

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

craft rides

The chance to purchase exclusive PRO Family merchandise

And more!

To order PRO merchandise, complete the order form you receive with your mem-

bership packet, take the form to your Polaris dealer and pay for the merchandise.

The merchandisewillbe shipped directly to your home fromthe PRO merchandise

fulfillment center.

Watch for your PRO membership packet and the next issue of PRO Spirit maga-

zine. This quarterly magazine will keep you informed about Polaris news and

events, and special PRO merchandise, travel, and ride opportunities.

Enjoyyour new Polaris vehicle,and welcome to thefamily--The Polaris PRO Fami-

ly.

CONTENTS

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

SAFETY WARNING AND OPERATION DECALS 3-13...........

DAILY PRE-RIDE INSPECTION 14...........................

OPERATION WARNINGS 15-33..............................

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

CONTROL AND PARTS FUNCTIONS 35-54...................

STARTING THE ENGINE 55.................................

VEHICLE BREAK IN PERIOD 56-57..........................

RIDING GEAR 58...........................................

CARRYING LOADS 59......................................

CARGO WEIGHT DISTRIBUTION 60.........................

DAILY PRE-RIDE INSPECTION 61...........................

RIDING 62-72..............................................

BATTERY 73-74............................................

NOISE EMISSION CONTROL SYSTEM REGULATION 75.......

MAINTENANCE 76-121.....................................

TROUBLE SHOOTING 122.................................

W ARRANTY 123-124.......................................

INDEX 125................................................

UNDERSTANDING WARNINGS

ATTENTION:

This is an ADULT VEHICLE ONLY; not a toy. Operation is prohibited for any-

one under 16 years of age. READ AND UNDERSTAND WARNINGS AND

OWNER’S MANUAL BEFORE OPERATION.

KNOW YOUR VEHICLE BEFORE YOU BEGIN RIDING!

Read this manual thoroughly referring to the various areas which are being dis-

cussed on your machine. Operating this vehicle carries with it responsibilities for

your personal safety, the safety of others, and the protection of our environment.

SAFETY TRAINING

When you purchasedthis vehicle yourdealerpresenteda hands-onsafety training

course covering all aspects of ATV safety. In addition, you were provided with cer-

tain printed material which instructs you on safe operating procedures.

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

a used Polaris ATV from a party other than a Polaris dealer, you can obtain this

safety training at no charge from any authorized Polaris dealer.

Failure to follow the warnings contained in this manual can result in SERIOUS IN-

JURY OR DEATH.

NOTE: Illustrations used in this manual are for general representation only.

Your model may differ.

UNDERSTANDING WARNINGS

SAFETY ALERT

The following precautionary signal words are used throughout this manual to con-

vey the following messages:

This is the safety alert symbol. When you see this symbol

on your machine or in this manual, be alert to the potential

for personal injury. Your safety is involved!

WARNING

Indicates a potential hazard

which could result in serious

injury or death.

CAUTION

Indicates a potential hazard which

may result in minor personal inju -

ry or damage to the ATV.

NOTE

The word “NOTE:” in this manual will alert

you to key information or instructions.

WARNING

HAZARD

Failure to heed WARNINGS.

WHAT CAN

HAPPEN

WARNINGS identify special instructions or procedures which, if not cor-

rectly followed, could result in personal injury, or loss of life.

HOW TO AVOID THE

HAZARD

Read all WARNINGS in this manual carefully and for y our safety be

sure to follow their instructions.

SAFETY WARNING AND OPERATION DECALS

NOTE:

Warning decals have been placed on the vehicle for your protection. Read and

follow the instructions on each decal carefully. In the event any decal becomes il-

legible or comes off, contact your Polaris dealerfor a replacement. Any safety de-

calneeding replacementwillbe providedby Polaris at no charge. The partnumber

is printed on the decal.

SAFETY WARNING AND OPERATION DECALS

7077919

E1997

SAFETY WARNING AND OPERATION DECALS

25_

READ AND UNDERSTAND WARNINGS AND OWNER’S MANUAL BEFORE

OPERATION. SEVERE INJURY OR DEATH CAN RESULT FROM IGNORING

WARNINGS OR IMPROPER USE. IF YOU DO NOT HAVE THE OWNER’S

MANUAL FOR THIS VEHICLE. CALL 1-800-342-3764 TO HAVE ONE

PROVIDED AT NO EXTRA CHARGE.

TO REDUCE TIPOVER RISK, BE ESPECIALLY CAREFUL WHEN

ENCOUNTERING OBSTACLES AND SLOPES, WHEN BRAKING ON HILLS

OR DURING TURNS.

KEEP FEET ON FOOTRESTS AT ALL TIMES.

HILL CLIMBING IS DANGEROUS, and should be attempted only by

experienced operators. Start on shallow slopes and practice procedures

described in Owner’s Manual before trying steeper terrain. Some hills are too

steep to safely stop or recover from an unsuccessful climbing attempt.

Effectiveness of brakes is significantly reduced on hills.

Never operate this ATV on grades steeper than 25 degrees . If vehicle slides

backwards down hill, apply hand brakes with gradual, even pressure to avoid

flipover. Never open throttle suddenly as flipover may result.

REDUCE SPEED when operating this vehicle on rough or hilly terrain, or when

carrying cargo on the racks.

REVERSE OPERATION CAN BE DANGEROUS even at low speeds. Steering

control becomes difficult. When backing up, proceed slowly and apply hand

brakes carefully; aggressive braking may result in flipover . Avoid backing

downhill. Avoid turning at sharp angles in reverse.

USE OVERRIDE FOR REVERSE SPEED LIMITER WITH CAUTION; Itallows

full engine power and can result in excessive speeds. Never activate override

button while throttle is open, as loss of control may result.

STOPPING DISTANCE MAY INCREASE with wet brakes or on wet surfaces.

AUXILIARY FOOT BRAKE: The right foot auxiliary brake pedal operates the

rear brake only. When backing up or when operating on hills, avoid sudden use

of the auxiliary brake; aggressive braking may result in flipover .

PARK BRAKE MAY RELAX WHEN USED FOR LONG PERIODS. When

parking on grades, leave the gear shift in forward and don’t leave brake

engaged for more than 5 minutes.

VEHICLE DESIGNED MAINLY FOR WARM WEATHER USE. Throttle linkage

and brakes may stick if operated in freezing weather, causing loss of control.

Dirt, mud, water , or other contaminants can also affect operation of controls.

Check both frequently.

ENGINE SHUT OFF SWITCH is available for use in event of throttle failure or

other emergency when engine shut off is desired.

NEVER PERMIT A GUEST TO OPERATE THIS ATV unless the guest has

read the Owner’s Manual and all labels, and has completed a certified training

course.

7078354

CAUTION: Do not shift transmission while vehicle is moving.

WARNING

SAFETY WARNING AND OPERATION DECALS

WARNING

OVER-LOADING CAN CAUSE STEERING,

TIPPING AND BRAKING PROBLEMS RE-

SU LTING IN LOS S OF CON TROL .

LOSS OF CONTROL CAN CAUSE SEVERE

INJURY OR DE ATH.

DO NOT OVERLOAD THE ATV.

SEE YOUR OWNER’S MA NUAL.

7072786

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.

7074954

(Found on models with no racks)

(Found on models with racks)

“IMPROPER TIRE PRESSURE OR

OVERLOADING CAN CAUSE LOSS

OF CONTROL.

LOSS OF CONTROL CAN RESULT IN

SEVERE INJURY OR DEATH.”

TIRE PRESSURE (PSI):

FRONT __ REAR __

MAXIMUM WEIGHT CAPACITY

(Gross Vehicle Weight)

INCLUDING MACHINE, DRIVER

AND CARGO IS ______ LBS.

(Refer to your Owner’s

Manual Supplement for your

vehicle’s specifications.)

Operating this ATV if you are under the age

of 16 increases your chance of severe injury

or death.

NEVER operate this ATV if you are under

age 16.

7078253

SAFETY WARNING AND OPERATION DECALS

WARNING

LOAD DISTRIBUTION WARNINGS

Correct loading of this vehicle is necessary to maintain proper stability and operating char-

acteristics. Overloading or incorrect positioning of the load effects the vehicles turning,

stopping distance and stability. Failure to follow loading requirements could cause severe

injury or death. REDUCE SPEED AND ALLOW GREATER DISTANCE FOR BRAKING

WHEN CARRYING CARGO.

CARGO WEIGHT DISTRIBUTION should be 1/3 on the front rack and 2/3 on the rear rack.

When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driv-

ing conditions. Maximum cargo capacity is 270 lbs. on level terrain. When operating at

maximum cargo capacity, the cargo weight distribution must be 90 lbs. on the front rack and

180 lbs. on the rear rack.

ALL LOADS MUST BE SECURED BEFORE MOVING VEHICLE. Unsecured loads can

create unstable operating conditions which could result in loss of control of the vehicle.

LOADS MUST BE CARRIED AS LOW ON THE RACKS AS POSSIBLE. Carrying loads

high on the racks raises the center of gravity of the vehicle and creates a less stable operat-

ing condition. When cargo loads are carried high on the racks, the weight of the loads must

be reduced to maintain stable operating conditions.

OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When handling off-

centered loads which cannot be centered, securely fasten load and operate with extra cau-

tion.

EXTREME CAUTION MUST BE USED when operating with loads extending over the rack

sides. Stability and maneuverability may be adversely affected, causing the machine to

overturn.

DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the front rack.

SEE YOUR OWNER’S MANUAL.

7074110

This decal is found only on models with dual racks.

SAFETY WARNING AND OPERATION DECALS

WARNING

RACK LOAD WARNINGS

Correct loading of this vehicle is necessary to maintain proper stability and operating

characteristics. Overloading or incorrect positioning of the load effects the vehicles

turning, stopping distance and stability. Failure to follow loading requirements could

cause severe injury or death. REDUCE SPEED AND ALLOW GREATER

DISTANCE FOR BRAKING WHEN CARRYING CARGO.

MAXIMUM CARGO CAPACITY is 125 lbs. on level terrain. When operating over

rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions.

ALL LOADS MUST BE SECURED BEFORE MOVING VEHICLE. Unsecured loads

can create unstable operating conditions which could result in loss of control of the

vehicle.

LOADS MUST BE CARRIED AS LOW ON THE RACK AS POSSIBLE. Carrying

loads high on the rack raises the center of gravity of the vehicle and creates a less

stable operating condition. When cargo load is carried high on the rack, the weight

of the load must be reduced to maintain stable operating conditions.

OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When

handling off-centered loads which cannot be centered, securely fasten load and

operate with extra caution.

EXTREME CAUTION MUST BE USED when operating with loads extending over

the rack sides. Stability and maneuverability may be adversely affected, causing the

machinetooverturn.

SEE YOUR OWNER’S MANUAL. 7074173

This decal is found on models with only rear racks.

SAFETY WARNING AND OPERATION DECALS

ATTENTION

DOPERA TION OF THIS VEHICLE WITHOUT

THE FIL TER ELEMENT WILL SEVEREL Y

DAMAGE THE ENGINE.

DCLEAN AIR FILTER OFTEN, MORE FRE-

QUENT CLEANING REQUIRED IN

DUSTY CONDITIONS.

DLiutilisation de ce véhicule sous liélément

filtre endommage sévèrement le moteur.

DNettoyer souvent le filtre à air, surtout dans

des situations poussiereuses.

7072791

(Under Seat)

(on rear of seat)

SAFETY WARNING AND OPERATION DECALS

MOV ING PARTS HAZ ARD 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

7078689

SAFETY WARNING AND OPERATION DECALS

ALL WHEEL

DRIVE

SWITCH

Do not push switch to

engage AWD if the rear

wheels are spinning.

This may cause severe

drive shaft and clutch

damage.

See your Owner’s

Manual.

7074935

MANUFACTURED

BY: POLARIS IND

DATE:

VIN:

THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND

IS NOT INTENDED FOR USE ON PUBLIC ROADS.

PRINTED IN U.S.A.

7077185

CE VÉHICULE EST UN VÉHICULE TOUT TERRAIN

QUI NiEST PAS DESTINÉ À ÊTRE UTILISÉ SUR

LES CHEMINS PUBLICS.

ATTENTION

Specific carburetor jetting and adjustments are required depending on

temperature and altitude. See your Owner’s Manual.

Factory setting:

40° to 80° F. at 0-3000 feet. (+5° to 26° C. at 0-900 meters ). 7073761

TRAILER MAX.

WEIGHT 850 LBS.

HITCH MAX. VERTICAL

WEIGHT 30 LBS.

POIDS MAX. DE

REMORQUE 386 KG.

POIDS MAX.

VERTICAL D’ATTACHE

14 KG.

OVERRIDE

SWITCH

Reverse override

and all wheel drive

activation in reverse

is controlled by the

override switch.

See your Owner’s

Manual.

7076273

Reverse Speed is

limited.

Reverse override is

controlled by the

override switch.

See your Owner’s

Manual.

OVERRIDE

SWITCH

7076274

AWD Models 2WD Models

7077542

TRAILER MAX WEIGHT:

1250 LBS. (568 KG) ON LEVEL GROUND

850 LBS. (368 KG) UP TO 15° GRADE

HITCH MAX. VERTICAL WEIGHT: 30 LBS. (14KG)

7072533

Chain Freeplay Is

Important. Adjust

Freeplay to 3/16″ -- 3 / 8 ″

DO NOT Overtension.

See Owner’s Manual.

Torque Eccentric Bolts To

60 Ft. Lbs.

7077618

DAILY PRE-RIDE INSPECTION

Inspect your ATV each time before riding to ensure it is in proper working or-

der. If proper inspection is not done, severe injury or death could result.

WARNING

If a proper inspection is not performed serious injury or death can result.

Always inspect your ATV before riding following the checklist carefully.

Before riding your vehicle, inspect all operating controls and parts.

Item/Inspection Procedure

1.Tires - check condition and pressures

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

3.All brakes - checkoperation,adjustment and fluidlevel (includesauxil-

iary brake)

4.Throttle - check for free operation and closing

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

and switches

6.Engine stop switch - check for proper function

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

axle nuts are secured by cotter pins

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

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

10.Steering - check for free operation noting any unusual looseness in

any area

11.Loose parts - visually inspectvehicle for any damaged or loose nuts/

bolts or fasteners

12.Operators helmet, goggles and clothing

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

at the recovery bottle

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD

Operating this ATV without proper instruction.

WHAT CAN

HAPPEN

The risk of an accident is greatly increased if the operator does not

know how to operate the ATV properly in different situations and on dif-

ferent types of terrain.

HOW TO AVOID THE

HAZARD

Beginning and inexperienced operators should complete the certified

training course offered by Polaris Industries Inc. They should thenreg-

ularly practice the skills learned in the course and the operating tech-

niques described in the Owner’s Manual.

For more information about the training course, contact an authorized

ATV dealer or call Polaris at 1-800-342-3764.

POTENTIAL

HAZARD

Failure to follow the age recommendations for this ATV.

WHAT CAN

HAPPEN

Use by children of ATVs that are not recommended for their age can

lead to severe injury or death of the child.

Even though a child maybe within the age group forwhich some ATVs

are recommended, he or she may not have the skills, abilities, or judg-

ment needed to operate the ATV safely and may be involved in a seri-

ous accident.

HOW TO AVOID THE

HAZARD

No one under 16 should operate a Polaris ATV.

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD

Carrying a passenger on this ATV.

WHAT CAN

HAPPEN

Greatly reduces your ability to balance and control this ATV.

Couldcause an accident,resulting in harmtoyou and/oryourpassenger.

HOW TO AVOID THE

HAZARD

Never c arry a passenger. The long seat is to allow the operator to shift

position as needed during operation. It is not for carrying passengers.

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD

Operating this ATV on paved surfaces, including sidewalks, paths,

parking lots, and driveways.

WHAT CAN

HAPPEN

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

seriously affect handling and control of the ATV, and may cause the

vehicle to go out of control.

HOW TO AVOID THE

HAZARD

Avoid operating the ATV on pavement whenever possible. If you

must ride on a paved surface, go slowly and do not make sudden

turns or stops.

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD

Operating this ATV on public streets, roads or highways.

WHAT CAN

HAPPEN

You can collide with another vehicle.

HOW TO AVOID THE

HAZARD

Never operate this ATV on any public street, road or highway, even

a dirt or gravel one.

In many states it is illegal to operate ATVs on public streets, roads

and highways.

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD

Operating this ATV without wearing an approvedhelmet, eye protection

and protective clothing.

WHAT CAN

HAPPEN

Operating without an approved helmet increases your chances of a s e-

vere head injury or death in the event of an accident.

Operating without eye protection can result in an accident and in-

creases your chances of a severe injury in the event of an accident.

HOW TO AVOID THE

HAZARD

Always wear an approved helmet which fits properly.

You should also wear:

Deye protection (goggles or face shield);

Dgloves;

Dboots;

Dlong-sleeved shirt or jacket; and

Dlong pants.

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD

Operating this ATV after consuming alcohol or drugs.

WHAT CAN

HAPPEN

Could seriously affect your judgment.

Could cause you to react more slowly.

Could affect your balance and perception.

Could result in an accident.

HOW TO AVOID THE

HAZARD

Never c onsume alcohol or drugs before or while driving this ATV.

POTENTIAL

HAZARD

Operating this ATV at excessive speeds.

WHAT CAN

HAPPEN

Increases yourchances of losingcontrol ofthe ATV, which can result

in an accident.

HOW TO AVOID THE

HAZARD

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

operating conditions; and your experience.

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD

Attempting wheelies, jumps and other stunts.

WHAT CAN

HAPPEN

Increases the chance of an accident, including an overturn.

HOW TO AVOID THE

HAZARD

Neverattemptstunts,suchas wheelies or jumps. Don’t try to showoff.

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD

Failure to inspect the ATV before operating.

Failure to properly maintain the ATV.

WHAT CAN

HAPPEN

Increases the possibility of an accident or equipment damage.

HOW TO AVOID THE

HAZARD

Always inspectyour ATV each time you use itto make sure the ATV

is in safe operating condition.

Always follow the inspection and maintenance procedures and

schedules described in the Owner’s Manual.

POTENTIAL

HAZARD

Removing hands from handlebars or feet from footrests during op-

eration.

WHAT CAN

HAPPEN

Removing even one hand or foot can reduce your ability to control

the ATV or could cause you to lose your balance and fall off the ATV.

If you remove a foot from the footrest, your foot or leg may come into

contactwith the rearwheels,whichcould injure you or cause anacci-

dent.

HOW TO AVOID THE

HAZARD

Alwayskeep bothhands onthe handlebarsand bothfeeton thefoot-

rests of your ATV during operation.

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD

Failure to use extra carewhen operatingthis ATVon unfamiliarterrain.

WHAT CAN

HAPPEN

You can come upon hidden rocks, bumps, or holes, without enough

time to react.

Could result in the ATV overturning or going out of control.

HOW TO AVOID THE

HAZARD

Go slowly and be extra c areful when operating on unfamiliar terrain.

Always be alert to changing terrain conditions when operating the

ATV.

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD

Failure to use extra care when operating on excessively rough, slip-

pery or loose terrain.

WHAT CAN

HAPPEN

Could cause loss of traction or vehicle control, which c ould result in

an accident, including an overturn.

HOW TO AVOID THE

HAZARD

Do not operate on excessively rough, slippery or loose terrain until

you have learned and practiced the skills necessary to control the

ATVonsuchterrain.

Always be especially cautious on these kinds of terrain.

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD

Turning improperly.

WHAT CAN

HAPPEN

ATV could go out of control, causing a collision or overturn.

HOW TO AVOID THE

HAZARD

Alwaysfollow properprocedures forturningas described in the Own-

er’s Manual. See page 63 .

Practice turning at low speeds before attempting to turn at faster

speeds.

Do not turn at excessive speed.

POTENTIAL

HAZARD

Operating on excessively steep hills.

WHAT CAN

HAPPEN

The vehicle can overturn more easily on extremely steep hills than on

level surfaces or small hills.

HOW TO AVOID THE

HAZARD

Never operate the ATV on hills too steep for the ATV or for your abilities.

Practice on smaller hills before attempting large hills.

Never operate ATV on hills steeper than 25_.

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD

Climbing hills improperly.

WHAT CAN

HAPPEN

Could cause loss of control or cause ATV to overturn.

HOW TO AVOID THE

HAZARD

Always follow proper procedures for climbing hills as described in the

Owner’s Manual. See pages 65 through 68.

Always check the terrain carefully before you start up any hill.

Never climb hills with excessively slippery or loose surfaces.

Shift your weight forward.

Neveropen the throttle suddenly. The ATV could flipover backwards.

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

drop, or another vehicle or person could be on the other side of the

hill.

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD

Going down a hill improperly.

WHAT CAN

HAPPEN

Could cause loss of control or cause ATV to overturn.

HOW TO AVOID THE

HAZARD

Always follow properprocedures for going down hills as described in

the Owner’s Manual. See page 67. NOTE: A special technique is

required when braking as you go downhill.

Always check the terrain carefully before you start down any hill.

Shift your weight backward.

Never go down a hill at high speed.

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

lean sharply to one side. Go straight down the hill where possible.

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD

Improperly crossing hills or turning on hills.

WHAT CAN

HAPPEN

Could cause loss of control or cause ATV to overturn.

HOW TO AVOID THE

HAZARD

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

tered the turning technique as described in the Owner’s Manual on

level ground. See page 68. Be very careful when turning on any hill.

Avoid crossing the side of a steep hill if possible.

When crossing the side of a

hill:

Alwaysfollow properprocedures as described intheOwner’sManual.

Avoid hills with excessively slippery or loose surfaces.

Shift your weight to the uphill side of the ATV.

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD

Stalling, rolling backwards or improperly dismounting while climbing a hill.

WHAT CAN

HAPPEN

Could result in ATV overturning.

HOW TO AVOID THE

HAZARD

Maintain steady speed when climbing a hill.

Ifyouloseallforward

speed:

Keep weight uphill.

Apply the brakes.

Lock parking brake after y ou are stopped.

If you begin rolling

backwards:

Keep weight uphill; never apply engine power.

Never apply the rear brake while rolling backwards.

Apply the single-lever brake gradually.

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

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

Turn the ATV around and remount, following the procedure described in

the Owner’s Manual. See page 68.

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD

Improperly operating over obstacles.

WHAT CAN

HAPPEN

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

HOW TO AVOID THE

HAZARD

Before operating in a new area, check for obstacles.

Use extreme caution when riding over largeobstacles, such as large rocks

or fallen trees.

If you cannot avoid obstacles, always follow proper procedures as de-

scribed in the Owner’s Manual.

POTENTIAL

HAZARD

Skidding or sliding.

WHAT CAN

HAPPEN

You may lose control of the ATV.

You may also regain traction unexpectedly, which may cause the ATV to

overturn.

HOW TO AVOID THE

HAZARD

On slippery surfaces, such as ice, go slowly and be very cautious in order

to reduce the chance of skidding or sliding out of control.

POTENTIAL

HAZARD

Riding on frozen lakes and rivers.

WHAT CAN

HAPPEN

Severe injury or death can result if the ATV and/or the operator break

through the ice.

HOW TO AVOID THE

HAZARD

Never ride your ATV on a frozen body of water before you are sure the ice

isthickenough and sound enough to supportthe machineand itsoperator,

as well as the force that is created by a moving vehicle.

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD

Operating this ATV through deep or fast flowing water.

WHAT CAN

HAPPEN

Tires may float, causing loss of traction and loss of control, which

could lead to an accident.

HOW TO AVOID THE

HAZARD

Never operate this ATV in fast flowing water or in water deeper than

that specified in your Owner’s Manual. See page 69.

Remember that wet brakes may have reduced stopping ability. Test

your brakes after leaving water. If necessary, apply them several

times to let friction dry out the pads.

POTENTIAL

HAZARD

Improperly operating in reverse.

WHAT CAN

HAPPEN

You could hit an obstacle or person behind you, resulting in serious

injury.

HOW TO AVOID THE

HAZARD

When you select reverse gear, make sure there are no obstacles or

people behind you. When it is safe to proceed, go slowly.

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD

Operating this ATV with impropertires, or with improper or uneven tire

pressure.

WHAT CAN

HAPPEN

Use of impropertires on this ATV, oroperationof this ATV with improp-

er or uneven tire pressure, may cause loss of control, and increases

the risk of an accident.

HOW TO AVOID THE

HAZARD

Always use the size and type tires specified in the Owner’s Manual

Supplement for this vehicle.

Always maintain proper tire pressure as described in the Owner’s

Manual Supplement.

POTENTIAL

HAZARD

Operating this ATV with improper modifications.

WHAT CAN

HAPPEN

Improper installation ofaccessories ormodification of this vehicle may

cause changes in handling which in some situations could lead to an

accident.

HOW TO AVOID THE

HAZARD

Never modify this ATV through improper installation or use of acces-

sories. All parts and accessories added to this vehicle should be gen-

uine Polaris Industries Inc. or equivalent components designed for

use on this ATV; and should be installed and used according to

instructions. If you have questions, consult an authorized Polaris ATV

dealer.

OPERATION WARNINGS

WARNING

POTENTIAL HAZARD

Overloading this ATV or carrying or towing cargo improperly.

WHAT CAN

HAPPEN

Could cause changes in vehicle handling which could lead to an ac-

cident.

HOW TO AVOID THE

HAZARD

Never exceed the stated load capacity for this ATV.

Cargo should be properly distributed and securely attached.

Reduce speed when carrying cargo or pulling a trailer. Allow greater

distance for braking.

Alwaysfollow the instructions in theOwner’s Manual for carryingcar-

go or pulling a trailer. See pages 59 and 60.

After a rollover or an accident, have a qualified service dealer check

the complete machine including,but notlimited to,brakes,throttle and

steering for possible damage.

WARNING

Safe operation of this rider active vehicle requires good judgement

and physical skills. Persons with cognitive or physical disabilities

who operate this vehicle have an increased risk of overturns and

loss of control which could result in serious injury or death.

CAUTION: Keep combustible materials away from exhaust system. Fire may re-

sult.

VEHICLE IDENTIFICATION NUMBERS

2Onrecoil

housing

1 VIN on the lower left

side of the frame tube

Important: Record these numbers from your ATV in the spaces provided.

1. Frame VIN

2. Engine Serial Number (Right front side of engine crankcase)

Remove the spare key and store in a safe place. Your key can be duplicated

only by obtaining a key blank from Polaris and having itcut by matingit with your

existing key.

The vehicle frame and engine serial numbers are important for modelidentifica-

tion when registering y our vehicle, obtaining insurance or whenever replace-

ment parts are required. In the event your vehicle were stolen these numbers

are essential to the recovery and identification of your ATV.

Dealer Imprint

CONTROL AND PARTS FUNCTIONS

Engine Electrical Switches

1. Override Switch (Reverse Speed Limiter) - This vehicle is equipped with a re-

verse speed limiter system. To obtain additional power while backing up, depress

the override button. WARNING: Never activate the override button while throttle

is open as loss of control may result, causing severe personal injury or

death.NOTE: The override switch also allows activation of Demand 4 Drive (All

Wheel Drive) in reverse, if Demand 4 Drive switch is on.

2. Main Switch - This switc h must be turned clockwise to the “on” position to start

the engine.

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

switch is in its “off” position. Its purpose is to provide the operator with a quick

means of engine shutdown in case of stuck throttle or other emergency. NOTE:

Both the main switch and the emergency engine stop switch shut off all electrical

powertothe entire vehicle including lights. Tostop the engine,slidethestopswitch

right or left to the “off” position.

4. Engine Start Button -Slide the stop switch to the center“run” position and push

up to start.

WARNING

Backing your ATV can be dangerous!

You could hit an obstacle or person behind you; or the vehicle could tip

over rearward on a steep incline causing severe injury or death.

Alwaysback slowly avoiding excessive speed anddo notuse thereverse

speed override switch system unless additionalpower is required forve-

hicle movement.

Avoid backing on steep inclines.

Avoid turning at sharp angles in reverse.

RUN

OFFOFF

Push Up to Start

CONTROL AND PARTS FUNCTIONS

Light Switches and Indicator Lights

Switches

Each Polaris ATV has a main switch. It is located on the right hand side of the ma-

chine and operated with a key.

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

lights on and off, it also switches the lights from Hi to Lo on models equipped with

Hi-Lo beams. NOTE: Will not light unless the main switch is on.

Indicator Lights

Each Polaris ATV has indicator lights. The configuration of these lights differs with

individual models and not every model is equipped with all the lights. The informa-

tion inyourOwner’s ManualSupplement and in the following box willhelp you iden-

tify the lights on your machine and their function.

High Beam Indicator (Blue)

Transmission Neutral

indicator - Green

Transmission Reverse

indicator - Yellow

All Wheel Drive

Indicator - Red

(Refer to page

43 for location)

Low Oil Warning

Light (Red)

Engine Hi Temp

Warning Indicator

If your machine has the following light configuration, use this diagram to de-

termine indicator light location and function.

Hi Temp Warning - Red (will

light only if engine overheats)

Neutral - Green

Reverse - Yellow

Located in LH switch on models equipped with Hi-Lo beam lights.

CONTROL AND PARTS FUNCTIONS

With engine running, verify function of indicator lights each time ATV is used.

W ARNING

This ATV is not equipped with highway approved lighting. This ATV is designed

for off-road use only and must not be ridden on streets or highways. Use caution

and drive at reduced speeds in conditions ofreduced visibility such as fog, rain and

darkness.

NOTE: The taillight is on wheneverthe mainswitch (key)is inthe on position. Turn

the k ey off to prevent battery drain.

indicates a potential hazard which

couldresult in serious injury ordeath.

WARNING

Electronic Speedometer

Some Polaris ATVs are equipped with an electronic speedometer which senses

vehicle speed from the right hand front wheel. The electronic speedometer mea-

sures distance in miles and kilometers as well as hours of operation. To display

each mode, press the button on the face of the speedometer once to “toggle”

through the functions. Each function will be displayed as follows:

Miles 00000.0 M

Trip Miles 000.0 M

Hours 00000.0 H

To reset Trip Miles:

1.Toggle to Trip Miles

2.Hold down button approximately 4 seconds.

To change distance measurement from Miles to Kilometers or vice versa:

1.Toggle to odometer.

2.Hold down the button approximately 8 seconds until the word FARIA appears

in the display, then release the button. If the last digit in the display is a “K”, the

measurement is Kilometers,ifthe last digit is an“M”, themeasurement is Miles.

The speedometer also includes a reverse speed limitfunction thatlimits the ATV’s

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

information.

ATTENTION

Do not wash the electronic speedometer with a high pressure washer.

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

may allow water to enter the speedometer and cause damage to the

electronic components

CONTROL AND PARTS FUNCTIONS

Engine Throttle and Choke

Throttle Lever

Engine speed and vehicle move-

ment are c ontrolled by pressing the

throttle lever. The throttle lever is

spring loaded and engine speed re-

turns to idle when the lever is re-

leased. This vehicle is equipped

with a Polaris Electronic Throttle

Control (ETC) which is designed to

reduce the risk of a frozen or stuck

throttle. In the event the throttle

cable should stick in an open posi-

tion, the engine will stop and power

to the rear wheels will cease when

the operator releases the throttle le-

ver.

Choke Lever

Refer to the engine starting procedure on page 55 for c orrect choke and throttle

settings during starting.

WARNING

The Electronic Throttle Control (ETC) stops the engine in the event of

a throttle system malfunction and is provided for your safety. Do not at-

tempt to modify the ETC system or replace it with any after market

throttle mechanisms.

WARNING

Do not start or operate an ATV with sticking or improperly operating

throttle controls. A stuck or improperly operating throttle could cause an

accident resulting in severe injury or death.

Always contact your dealer for service repairs whenever throttle prob-

lems arise.

Failure to check or maintain proper operation of the throttle system can

result in the throttle lever sticking during riding and cause an accident.

Always check the lever for free movement and return before starting the

engine and occasionally during riding.

Throttle

Choke

CONTROL AND PARTS FUNCTIONS

Front and Rear Brakes

The brake fluid in the master cylinder,

which is located on the left handlebar,

should be checked before each ride.

The fluid level can be seen through the

plastic reservoir, and should be main-

tained between the indicated max and

min marks on the reservoir. NOTE:

When checking the fluid level, the ATV

must be on level ground the the handle-

bars straight. If the fluid level is low add

DOT 3 (PN 2870990) only.

WARNING: Once a bottle of brake fluid is opened, use what is necessary and dis-

card the rest. Do not store or use a partialbottle of brake fluid. Brakefluid is hygro-

scopic, meaning it rapidly absorbs moisture from the air. This causes the boiling

temperature of the brake fluid to drop, which can lead to early brake fade and the

possibility of serious injury.

The front and rear brakes are applied by squeezing the left sidebrake levertoward

the handlebar. The front and rear brakes are hydraulically activated disc type

brakes which are activated by one lever only.

Always test brake lever travel and reservoir 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

Operating theATVwith a spongy brakelevercan resultinlossof braking.

Loss of braking could cause an accident.

Never operate the ATV with a spongy feeling brake lever.

Master Cylinder

Reservoir

Max

Min

CONTROL AND PARTS FUNCTIONS

Parking Brak e

Setting the Parking Brake

1.Squeeze the left hand brake lever two

or three times and hold it.

2.Rotate the park brake lock into the

notcheson the master cylinderbody.

Release the brake lever.

3.To release the parking brake lock,

squeeze the brake lever. It willreturn

to its released position.

WARNING

Always check to be sure that the parking brake has been disengaged

before operating the ATV. An accident could result if the parking

brake is left on while the ATV is operated.

The parking brake may relax when left on for a long period of time.

This could cause an accident.

Do not leave the vehicle on a hill depending on the parking brake

for more than five minutes.

Always block the downhill side of the wheels if leaving the ATV on a

hill or park the ATV in a side hill position.

Auxiliary Power Outlet

Auxiliary power outlets provide 12V power for operating accessoriessuch as hand

held spot lights.

Outlets are located on the front headlight pod and/or rear taillight bracket.

Do not use front and rear outlets simultaneously as increased battery drain will re-

sult.

To determine if your vehicle is equipped with auxiliary power outlets, please check

your Owner’s Manual Supplement.

Parking Brake Lock

Minimum

Maximum

CONTROL AND PARTS FUNCTIONS

Auxiliary Brake

Your Polaris ATV has an auxiliary brake provided as a safety feature. It is located

on the inside of the right floor board and is operated by the right foot. It is intended

as a backup tothemainbrake system,especiallyifthe mainsystem becomesinop-

erative.

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

sively apply the auxiliary brake when going forward or the rear wheels may skid

and slide sideways causing loss of control. If the rear wheels slide, reduce brake

pedal pressure to brake the rear wheels without skidding. Aggressively applying

the rear brake when backing down a hill may cause rear tip over.

Brake Fluid Level

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

The reservoir is located under the seat or near the foot brake. The fluid should be

kept between the maximum and minimum marks.

Auxiliary Brake

Pedal

CONTROL AND PARTS FUNCTIONS

Transmission Gear Selector Operation

Shift patterns depend on the type of vehicle

you own. Please check your Owner’s

Manual Supplement to define your ma-

chine’s shift pattern.

The transmission gear selector is located

on the right side of the vehicle directly

above and forward of the engine recoil

starter. The transmission selector lever

has three or fourpositions:high forward;re-

verse; neutral; and low forward or forward;

reverse; and neutral. Check your Owner’s

Manual Supplement for specification.

Use of low forw ar d gear is recommended in

heavy pulling situations to extend belt life.

To change gears,stop the vehicle and with the engine idling, move the lever to the

desired gear. Do not attempt to shift gears with engine speed above idle or while

the vehicle is moving.

Always place the transmission in gear with the parking brake locked whenever the

vehicle is left unattended.

Maintaining shift linkage adjustment is important to assure proper transmission

function. Should you experience any shifting problem see your dealer.

WARNING

1.Do not attempt to shift the transmission while the vehicle

is moving or while operating on hilly terrain.

2.Always place the transmission in gear with the parking

brake applied and turn the vehicle off whenever the ve-

hicle is left unattended.

Shift Patterns

CONTROL AND PARTS FUNCTIONS

Demand 4 Drive

AWD Switch

Exclusive Demand 4 Drive System (All Wheel Drive)

Polaris 4 wheel drive ATVs are equipped with a unique,Polaris exclusive,Demand

4 Drive (AWD) system which is activated by a switch on the right handlebar. When

the switch is “off” the 4x4 is in 2 wheel drive at all times. When the switch is “on”

the 4x4 is in Demand 4 Drive and the front wheels will automatically engage any-

time the rear wheels lose traction. When the rear wheels regain traction, the front

wheels will automatically disengage. NOTE: The override switch also allows ac-

tivation of Demand 4 Drive (AWD) in reverse, if Demand 4 Drive switch is on.

There is no limit to the length of time the vehicle may remain in Demand 4 Drive.

The Demand 4 Drive switch may be turned on or off while the vehicle is moving.

If the s witch is turned off when the front hubs are driving they will not release until

the rear wheels regain traction.

CAUTION: Do not switch on Demand 4 Drive if the rear wheels a re spinning. This

may cause severe drive shaft and clutch damage. Engage the Demand 4 Drive

switch before getting into conditions where frontwheel drive may be needed. If the

rear wheels are spinning, release the throttle before turning the Demand 4 Drive

switch on.

CONTROL AND PARTS FUNCTIONS

Disengaging Wheel Hubs

When backing uphillwhile inDemand 4 Drive and then going forward downhill,one

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

be disengaged by stopping, shifting to and moving in reverse. Then proceed in

forward again.

You can tell if only one front hub is engaged if the handlebars pull to one side. If

bothfront wheel hubs are engaged, steering effortincreases but remains balanced

from left to right, and vehicle speed is somewhat restricted.

WARNING: If both hubs were engaged and only one released during opera-

tion, loss of control could result. If you experience hub engaging symptoms, use

the above disengaging technique before proceeding. Failure to disengage front

hubs as directed above could result in severe injury or death.

Ifthe hubs remainengaged after following these instructionsreturn theATV toyour

dealer for service.

PVT System

WARNING

The PVT system rotates at high speeds, creating large amounts of force

on clutch components. Extensive engineering and testing has been con-

ducted to insure the safety of this product. However, as the owner you

have the following responsibilities to make sure this system remains safe:

DDo not modify any component of the PVT system. Doing so may re-

duce its strength so that a failure may occur at high speeds. This

system has been precision balanced. Any modification will cause the

system to be out of balance, creating vibration and additional loads

on components.

DRoutine maintenance is the responsibility of the owner. Always follow

recommended maintenance procedures. See your dealer!

DThis PVT system is intended for use on Polaris products only.

DThe PVT housing must be securely in place during operation.

Failure to comply with this warning can result in severe injury or death.

CONTROL AND PARTS FUNCTIONS

Engine Cooling System

Coolant Level

The recovery bottle, located on the

left side of the machine, must be

maintained between the minimum

and maximumlevelsindicated on the

recovery bottle.

The engine coolantlevel iscontrolled

or maintained by the recovery sys-

tem. The recovery system compo-

nents are the recovery bottle, radia-

tor filler neck, radiator pressure cap

and connecting hose.

As coolant operating temperature in-

creases, the expanding (heated) ex-

cess coolant is forced out of the ra-

diator past the pressure cap and into

the recovery bottle. As engine cool-

ant temperature decreases the c on-

tracting (cooled) coolant is drawn

back up from the tank past the pres-

sure cap and into the radiator.

NOTE: Some coolant level drop on

new machines is normal as the sys-

tem is purging itself of trapped air.

Observe coolant levels and maintain

as recommended by adding coolant

totherecovery bottle. Polaris recom-

mends 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. NOTE: Polaris Premium 60/40 is already premixed and ready to

use. Do notdilute withwater. NOTE: Always follow the manufacturer’s mixingrec-

ommendations for the freeze protection required in your area.

To access the recovery bottle on Gen IV machines it is necessary to remove the

left side panel as described on page 91.

Recovery Bottle

Gen III

Recovery

Bottle

Gen IV

CONTROL AND PARTS FUNCTIONS

Engine Cooling System

Radiator Coolant Level Inspection

NOTE: This procedure is only re-

quired ifthe cooling system has been

drained for maintenance and/or re-

pair. However, if the recovery bottle

has run dry, the level in the radiator

should be inspected and coolant

added if necessary.

WARNING Never remove the

pressure cap when the engine is

warm or hot. Escaping steam can

cause severe burns. The engine

must be cool before removing the

pressure cap.

To access the radiator pressure cap:

Gen III - To access the pressure cap,

clean the area around the oilcap and

remove the oil cap (2-cycle models).

Remove front cover by placing your

fingers under the front of the cover

and pulling upward. Reinstall oil cap.

Gen IV - Remove the four screw se-

curing front rack. Remove front cov-

er by placing your fingers under the

front of the cover and pulling upward.

NOTE: Use of a non-standard pres-

sure cap will not allow the recovery

system to function properly. If the

cap should need replacement con-

tact your dealer for the correct re-

placement part.

Engine Cooling System

To insure that the coolant maintains its ability to protect the engine, it is recom-

mended thatthesystembe completelydrainedevery twoyearsanda freshmixture

of antifreeze and water be added. Polaris recommends the use of Polaris Pre-

mium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum com-

patible anti-freeze/coolant and distilled water. NOTE: Polaris Premium 60/40 is

already premixed and ready to use. Do not dilute with water. IMPORTANT: Al-

ways follow the manufacturer’s mixing recommendations for the freeze protection

required in your area.

Using a funnel, slowly add coolant as necessary through the radiator filler neck.

Pressure Cap

Gen III

Rack

Front

Cover

Gen IV

CONTROL AND PARTS FUNCTIONS

Engine Fuel and Oil System

The fuel tank filler cap (1) is located directly behind the handlebar. Refer to your

owner’s ManualSupplement for tankcapacity. Use eitherleadedor unleadedgas-

oline with a minimum pump octane number of 87 R+ M/2 octane.

On models with a two cycle engine, the engine oil injection tank filler cap (2) is lo-

cated on the front of the machine. Refer to you Owner’s Manual Supplement to

determine the type of engine your vehicle has. The tank capacity is 2 quarts (1.9

l). CAUTION: To avoid serious engine damage always top off the oil level when

refueling.

CAUTION: On modelswith a twocycleengine,use onlyPolaris injectionoil. Never

substitute or mix oil brands. Serious engine damage and voiding of warranty can

result.

The fuel valve is located on the leftside of the front fender and has three positions:

OFF: For vehicle storage and whenev-

er transporting.

ON: For normal operation.

RES: For reserve supply in the event of

main supply exhaustion.

NOTE: There is about a 7 to 10 mile

(11.2 to 16 km) range on reserve gas.

Always refill the gas tank as soon as

possible after having used the reserve

supply.

Alwaysreturn valve to “on”position after

refueling machine.

OFF

RES

CONTROL AND PARTS FUNCTIONS

Engine Fuel Safety/Fuel/Filter

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

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

annually. Do not attempt to clean the fuel filter.

WARNING

Gasoline is highly flammable and explosive under certain conditions.

DAlways exercise extreme caution whenever handling gasoline.

DAlways refuel with the engine stopped and outdoors or in a well v enti-

lated area.

DDo not smoke or allow open flames or sparks in or near the area

where refueling is performed or where gasoline is stored.

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

DIf you get gasoline on your skin or clothing, immediately wash it off

with soap and water and change clothing.

DNever start the engine or let it run in an enclosed area. Gasoline

powered engine exhaust fumes are poisonous and can cause loss

of consciousness and death in a short time.

DShut off fuel valve whenever the ATV is stored or parked.

WARNING

The engine exhaust from this

product contains chemicals

known to cause cancer, birth de-

fects or other reproductive harm.

CONTROL AND PARTS FUNCTIONS

4-Cycle Premium 4 Synthetic Lubricant

Polaris Premium 4 All Season Synthetic engine oil has been specially formulated

forusein Polaris 4-cycle engines. Itis afullysynthetic,high performance,multi-vis-

cosity oil designed to provide the ultimate in lubrication performance and protec-

tion.

Premium 4 possesses unsurpassedfilm strength over thewidest possible temper-

ature range. It resists viscosity and frictional breakdown in ambient temperatures

from -40° F to 120° F. Its exceptional frictional properties result in more efficient

operation, more power output and lower fuel consumption.

Although Polaris Premium4 istheonly oilrecommended foruse in this engine,use

of any API certified “SH” oil is allowable. Oil may need to be changed more fre-

quently if Polaris Premium 4 is not used. You will also need to follow the manufac-

turers recommendations for ambient temperature operation.

Oil System

The oil tank is located on the left side of the vehicle or on the engine, depending on

the model. To check the oil:

1. Set machine on a level surface.

2. Start the engine and let it

idle for 20-30 seconds.

3. Stop the engine, remove

dipstick and wipe dry with a

clean cloth.

4. Screw in the dipstick

completely, remove it and

read the oil level. NOTE:

The dipstick must be

screwed in to keep the

angle and depth of stick

consistent.

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

marks. Add oil as indicated by the level on the dipstick. Do not overfill.

CAUTION: Use only Polaris Premium 4 All Season synthetic oil (PN 2871271), or

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

and voiding of warranty can result.

Oil and Filter Change

The recommended oil change interv al is 100 hours, 1000 miles, or every six

months, whichever comes first. Suggested break in oil change is at 20 hours, 500

miles, or one month, whichever comes first. Severe use operation requires more

frequent service. Severe use includes continuous duty in dusty or wet conditions,

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

10° F, and riding between 10° F and 30°F when mosttrips are slow speed and less

than 5 miles. Be sure to change the oil filter whenever changing oil

1. Place vehicle on a level surface.

2. Clean area around drain plug which is found at the bottom of the oil tank or on

the bottom of the engine.

ADD 8 OZ. NORMAL FULL

Maintain Oil Level In Normal Range

CONTROL AND PARTS FUNCTIONS

Oil and Filter Change (Cont.)

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

4. Place a drain pan beneath the plug and remove it. CAUTION: Oilmay be hot.

Do not allow hot oil to come into contactwith skin as serious burns may result.

5. Allow oil to drain completely.

6. Installanew sealing washer on oildrain plug. NOTE: The sealing surfaceson

the drain plug and the oil tank should be clean and free of burrs, nicks or

scratches.

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

8. Disconnect the

lower oil delivery

hose. Remove the

fitting (C) from the

oil tank. Clean the

fitting screen.

Reinstall the fitting

screen, torquing to

14-17 ft. lbs.

Reattach oil line. If

banjo fitting (D) is

used, torque to

14-17 ft. lbs. Ifhose

clamp (E) is used,

tighten securely.

9. Place shop towels

beneath oil filter.

Using an oil filter

wrench, turn filter

counterclockwise

to remove.

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

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

sure the O-Ring is in good condition. Also make sure the O-ring from the old

filter is not still on the engine.

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

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

remove drain plug foundon lowerrightside of crankcase. NOTE: The sealing

surfaces on the drain plug and crankcase should be clean and free of burrs,

nicks or scratches.

14. Reinstall drain plug.

CONTROL AND PARTS FUNCTIONS

15. Remove dipstick and add the amount of oil indicated in your Owner’s Manual

Supplement. Reinstall dipstick. NOTE: If sump is notdrained, add about 1 3/4

quarts initially.

16. Place gear selector in

neutral and set parking

brake.

17. Startengineand let it idle for

one to two minutes. Stop

engine and inspect for

leaks.

18. Re-check oil level on the

dipstick and add oil as

necessary to bring the level

to the upper mark on the

dipstick.

19. Dispose of used filter and oil properly.

Fuel Filter and Oil Filter

All Polaris ATVs are equipped with a unique in-line fuel filter.

These filters should be replaced by your dealer after every 100 hours of operation

or annually. Do not attempt to c lean these filters.

Dipstick

Filter

CONTROL AND PARTS FUNCTIONS

Polaris 2-Cycle Lubricants

Polaris has a family of premium oils available for use in all our products and highly

recommends their use. The only oils recommended for Polaris 2-cycle ATVs are

Polaris Premium 2-cycle oil or Premium Gold Synthetic 2-cycle oil.

CAUTION: Engine warranty coverage may become void if other

brands are substituted.

Polaris Premium 2-cycle lubricants are the most advanced formulation of oils spe-

cifically designed for today’s 2-cycle engines. Months of lab and field tests have

resulted in a new generation of 2-cycle lubricants. Polaris Premium 2-cycle lubri-

cants provide additives for 2-cycle engines lacking in today’s fuel that keep ring

grooves cleaner for less ring sticking and provide improved overall engine cleanli-

ness. With new generation lubricity technology, they excel in meeting the lubrica-

tion demands of today’s high performance 2-cycle engines. These are optimum

oils recommended for liquid cooled and air cooled 2-cycle engines. We believe

these oils are the best available in the market today.

Premium Gold Synthetic 2-Cycle Oil

Your vehicle has been primed with Premium Gold Synthetic oil. This lubricanthas

been specially formulated for low smoke, low odor and high lubricity. We recom-

mend continued use of this oil or Premium 2-cycle oil.

Premium 2-Cycle Oil

Polaris also has a TC-W3 premiumoilavailableforusein allof our2 cycleproducts.

We highly recommend its use if premium gold synthetic is not used. The only oil

recommended for this ATV is Polaris brand oil.

Polaris Premium 2-cycle oils will readily mix with each other, however do not mix

Polaris Premium 2-cycle oils with any other oils as theymay not be compatible and

engine damage may occur.

CONTROL AND PARTS FUNCTIONS

Recoil Starter

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

on the right side of the machine will allow vehicle operation until repairs can be

made.

Polaris 4-cycle engines are equipped with automatic decompressors. Thismakes

recoil starting possible by allowing compression to “leak” at cranking speeds. The

decompressor senses when the engine is spinning fast enough to start and re-

stores compression for starting.

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

page 40.

2.Take the machine out of gear.

3.Grasp the recoil starter tightly and pull slightly until the starter mechanism en-

gages.

4.Pull the rope abruptly to start the engine. CAUTION: Take care not to extend

the starter rope so far that it stops, causing damage to the recoil assembly.

CONTROL AND PARTS FUNCTIONS

Drain the recoil housing afteroperating theATV in verywetconditions. Thisshould

also be done before s toring the ATV. The drain screw is located at the bottom of

the recoil housing. Remove the screw with a 10mm wrench. Reinstall screwonce

housing has been drained.

CAUTION: Make sure the

manual start handle is fully

seated on the recoil housing,

especially when travelling in

wet areas. If it is not sealed

properly, water may enter the

recoil housing and damage

components.

Water will enter the recoil

housing ifthestarter handle is

disengaged from the rope

guide when under water.

After travelling in wet areas

the recoil housing and starter

should always be drained

completely by removing the

recoil.

Do not open the crankcase

drain unless the engine has

ingested water. On 4-cycle

engines, some engine oil will

be lost if crankcase drain is

opened.

On the Trail Blazer, the recoil

handle must be behind the heat

shield for it to seal properly. If it is

not sealed properly, water may

enterthe recoilhousing and dam-

age components.

Recoil

Drain

Crankcase Drain

Starter Pinion

Drain

250 and 400 Engines

Counter Balance

Drain (400s Only)

Recoil Drain (above front

propshaft on shaft drive models)

Crankcase Drain

4-Cycle Engines

STARTING THE ENGINE

Procedure for Starting a Cold Engine

1.Place the transmission in neutral and push the vehicle to a level surface.

2.Lock the parking brake.

3.Turn the fuel tank valve to ON.

4.Sit on the vehicle.

“HALF”

“FULL”

“OFF”

Choke Lever Top View

5.Move the choke lever to the FULL position.

6.Turn the ignition key to ON and the engine stop switch to RUN.

7.Press the starter button.

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

9.Press starterbuttonforfive seconds. If engine does notstart, release starterbut-

ton and wait five seconds; then press starter button for another five seconds.

Repeat this procedure until engine starts.

NOTE: Do not press the throttle while starting the engine.

After the Engine Starts

1.If the engine slows or stops, use of the choke lever at its HALF position will allow

proper engine warm up.

2.Vary the engine RPM slightly with the throttle to aid in warm up until the engine

idles smoothly. Then move the choke to OFF.

CAUTION: Proper engine warm up is essential each time before driving to avoid

engine damage.

WARNING

Carbon monoxide exhaust gas is poisonous!

Always start the ATV outdoors.

Never run the engine in an enclosed area.

VEHICLE BREAK-IN PERIOD

2-Cycle Engines

The break in period for your new Polaris ATV is defined as the time it takes to use

the first tank of gasoline. No single action on your part is as important as a proper

break in period. Careful treatment of a new engine will result in more efficient per-

formance and longerlifefortheengine. Performthefollowing procedurescarefully.

CAUTION: Use only Polaris injection oil. Never substitute or mix oil brands. Seri-

ous engine damage and voiding of warranty can result.

1.Mix 12.8 ounces of injection oilto fourgallons (or16ounces to5gallons)ofgaso-

line in a suitable gas can. Fill the fuel tank as outlined on pages 47 through 48.

2.Fill the oil tank with Polaris injection oil.

3.Drive slowly at first. Select an area which is open and will give you room to famil-

iarize yourself with vehicle operation and handling.

4.Vary the throttle positions. CAUTION: Do not operate at full throttle or high

speeds forextended periodsduring thefirstthree hours of use. Excessive heat

can build up and cause damage to close fitted engine parts.

5.Perform regular checks on fluid levels, controls and all important areas on the

vehicle as outlined earlier on the daily pre-ride inspection checklist found on

page 14.

After the break in period the oilinjection system provides the necessary engine lu-

brication without the need for pre-mixed fuel. CAUTION: To avoid serious engine

damage always fill the oil tank when refueling the ATV.

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

level in the oil tank has dropped, indicating that the oil pump is functioning

properly. If the level has not dropped, see your dealer for oil pump bleeding

and repeat the pre-mix procedure.

VEHICLE BREAK-IN PERIOD

4-Cycle Engines

The break in period for your new Polaris ATV is defined as the first ten hours of op-

eration,orthetime ittakes touse the firsttwo tanksfull of gasoline. No singleaction

on your part is as important as a proper break in period. Careful treatmentof a new

engine will result in more efficient performance and longer life for the engine. Per-

form the following procedures carefully.

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

“SH” oil. Never substitute or mix oil brands. Serious engine damage and voiding

of warranty can result.

1.Fill fuel tank with either unleaded or leaded fuel which has a minimum pump oc-

tane number of 87= (R+ M)/2.

2.Check oil reserv oir level indi-

cated on dipstick. Add oil if

necessary.

3.Drive slowly at first. Select

an area which is open and

will give you room to famil-

iarize yourself with vehicle

operation and handling.

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

operate at full throttle or high speeds for extended periods during the first three

hours of use. Excessive heat can build up and cause damage to close fitted

engine parts.

5.Perform regular checks on fluid levels, controls and all important areas on the

vehicle as outlined earlier on the daily pre-ride inspection checklist found on

page 14.

6.Pull only light loads.

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

ADD 8 OZ. NORMAL FULL

Maintain Oil Level In Normal Range

RIDING GEAR

Safe Riding Gear

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

special protective clothing which will make you feel more comfortable and reduce

chances of injury.

1. Helmet

Your helmet is the most important piece

of protective gear for safe riding. A hel-

met can prevent a serious head injury.

Select an approved helmet which meets

or exceeds yourstate’s safety standards

and bears either the Department of

Transportation (DOT) label, the Ameri-

can National Standards Institute label

(ANSI z 90.1), or the Snell Memorial

Foundation label.

2. Eye Protection

Do not depend on sunglasses for proper

eye protection. A pair of goggles or hel-

met face shield offer the best protection

foryoureyes. They should be kept clean

and be of shatterproof design (bearing

the markings z2.1 or VESC 8).

3. Gloves

Off-road style gloves with knuckle pads

are the best for comfort and protection.

4. Boots

The best footwear is a pair of strong over the calf type boots with heels, such as

moto-cross boots.

5. Clothing

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

with kneepads, a jersey and shoulder pads provide the best protection.

CARRYING LOADS

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

should be evenly distributed (1/3 on the front and 2/3 on the rear) and mounted as

low as possible. When operating over rough or hilly terrain, reduce speed and car-

go to maintain stable driving conditions. Never exceed the weights specified in

your Owner’s Manual Supplement.

Maximum trailer weight - 850 lbs.(386 kg); maximum vertical hitch weight - 30

lbs.(14kg). Selectmodels may towup to 1250 (568 kg) on level groundonly. Refer

to your Owner’s Manual Supplement to determine your machine’s capabilities.

IMPORTANT: Know your machine before your ride.

Maximum gradewhile trailertowing - 15°. Do not tow any traileron a gradesteeper

than 15 °.

If your machine is equipped with a front rack, take care when loading. Improper

loading of the front rack can obstruct the headlight beam, reducing night visibility.

Do not obstruct the headlight beam with cargo.

Use of low forward gear is recommended in heavy pulling situations to extend belt

life.

CARGO WEIGHT DISTRIBUTION

2/3 of Load on

Rear Rack

1/3 of Load on

Front Rack

RNING

Correct loading of this vehicle is necessary to maintain proper stability and

operating characteristics. Overloading or incorrect positioning of the load af-

fects the vehicle’s turning, stopping distance and stability. Failure to follow

loading requirements could cause severe injury or death. REDUCE SPEED

AND ALLOW GREATER DISTANCE FOR BRAKING WHEN CARRYING

CARGO.

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 one rack only

increases the possibility of vehicle tip over.

HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use

extreme caution when applying brakes with a loaded vehicle. Avoid terrain

or situations which may require backing downhill.

ALL LOADS MUST BE SECURED BEFORE MOVING VEHICLE. Unse-

cured loads can create unstable operating conditions, which could result in

loss of control of the vehicle.

LOADS MUST BE CARRIEDAS LOW ON T HE RACKS ASPOSSIBLE. Car-

rying loads high on the racks raises the c enter of gravity of the vehicle and

creates a less stable operating condition. When cargo loads are carried high

on the racks, the weight ofthe loadsmust be reduced tomaintain stable oper-

ating conditions.

OPERATE ONLY WITH STABLE ANDSAFELY ARRANGED LOADS. When

handling off-centered loads which cannot be centered, securely fasten load

and operate with extra caution. Always attach the tow load to the hitch point

designated for your ATV.

EXTREME CAUTION MUST BE USED when operating with loadsextending

overthe racksides. Stability and maneuverability may be adversely affected,

causing the machine to overturn.

DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on

the front rack.

DO NOT TRAVEL FASTER THANTHERECOMMENDEDSPEEDS. Vehicle

should never exceed 10 mph (16 kph) while towing a load on a level grass

surface. Vehicle speed should never exceed 5 mph (8 kph) when towing

loads in rough terrain, while cornering, or while ascending or descending a

hill.

DAILY PRE-RIDE INSPECTION

Inspect your ATV each time before riding to ensure it is in proper working or-

der. If proper inspection is not done, severe injury or death could result.

WARNING

If a proper inspection is not performed serious injury or death can result.

Always inspect your ATV before riding following the checklist carefully.

Before riding your vehicle, inspect all operating controls and parts.

Item/Inspection Procedure

1.Tires - check condition and pressures

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

3.All brakes - checkoperation,adjustment and fluidlevel (includesauxil-

iary brake)

4.Throttle - check for free operation and closing

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

and switches

6.Engine stop switch - check for proper function

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

axle nuts are secured by cotter pins

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

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

10.Steering - check for free operation noting any unusual looseness in

any area

11.Loose parts - visually inspectvehicle for any damaged or loose nuts/

bolts or fasteners

12.Operators helmet, goggles and clothing

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

at the recovery bottle

RIDING

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

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

gear.

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

4.Release the parking brake.

5.Slowly depress the throttle with y our right thumb and begin driving. Vehicle

speed is controlled by the amount of throttle opening and all transmission shift-

ing is done automatically.

6.Drive slowly, practice maneuvering and using the throttle and brakes on level

surfaces.

indicates a potential hazard which

couldresult in serious injury ordeath.

WARNING

RIDING

Making Turns

Practice making turns at slow speeds.

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

equally atalltimes. This meansthatthewheelon the outside of the turn musttravel

a greater distance than the inside wheel when turning and the inside tire must slip

traction slightly. To turn, steer in the direction of the turn leaning your upper body

to the inside of the turn while supporting your weight on the outer footrest. This

technique alters the balance of traction between the rear wheels allowing the turn

to be made smoothly. The same leaning technique should be used for turning in

reverse. WARNING: Avoid turning at sharp angles in reverse as tipover and seri-

ous injury may result.

indicates a potential hazard which

couldresult in serious injury ordeath.

WARNING

RIDING

Riding On Slippery Surfaces

Whenever riding on slippery surfaces such as wet trails or loose

gravel, or during cold freezing weather , special attention must be

paid to prevent vehicle turnover. Always:

1.Slow down when entering slippery areas.

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

turns which can cause skids.

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

your body weight forward.

4.Driving with Demand 4 Drive (All Wheel Drive) engaged can assist in controlling

the vehicle in slippery areas. CAUTION: Never engage Demand Drive while

wheels are spinning as severe damage to drive train may occur.

WARNING

Failure to exercise care when operating the ATV on slippery surfaces can

be dangerous.

Loss of tire traction and vehicle control can result in an accident, including

an overturn.

DNever apply brakes during a skid. Complete loss of ATV control can

result.

DDo not operate on excessively slippery surfaces if possible to avoid.

DAlways reduce speed and use additional caution.

RIDING

Traveling Uphill

25_ Maximum

Whenever traveling uphill always travel straight uphill and:

1.Avoid steep hills.

2.Keep both feet on the footrests.

3.Transfer your weight forward.

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

5.Remain alertandbe prepared to take emergency action. This may include quick

dismounting of the ATV.

WARNING

Braking and handling are greatly affected whenever operating in hilly ter-

rain.

Loss of vehicle control or overturning of the ATV could occur.

DAvoid operating on steep hills (25_ max imum).

DUse extreme care when operating your ATV in hilly terrain.

indicates a potential hazard which

couldresult in serious injury ordeath.

WARNING

RIDING

Sidehilling

Sidehilling your ATV is one of the most dangerous types of riding

and should be avoided if possible. In the event you do enter into a

situation where sidehilling is necessary, always:

1.Slow down.

2.Lean into the hill transferring your upper body weight toward the hill while keep-

ing y our feet on the footrests.

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

If vehicle begins to tip, quicklyturn the front wheel downhill, if possible, or dismount

on the uphill side immediately!

WARNING

Improperly crossing hills or turning on hills can be dangerous!

Loss of vehicle control or overturning of the ATV could occur.

DAvoid crossing the side of a steep hill if possible.

DUse extreme care when operating your ATV in hilly terrain.

RIDING

Traveling Downhill

Whenever descending a hill, always:

1.Drive directly downhill.

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

3.Slow down.

4.Apply the brakes slightly to aid in slowing.

Familiarize yourself with the auxiliary rear brake pedal and its use in the event loss

of normal s ervice brakes occurs.

WARNING

Loss of vehicle control due to excessive speed can occur. Loss of control

may result in serious injury or death.

RIDING

Turning Around On A Hill

8’

Uphill

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

maneuver which can be used when it is necessary to turn around

while climbing a hill is the K-turn.

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

2.Leave transmission in forward and shut off engine.

3.Dismount on left or uphill side of ATV.

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

5.While holding service brake, release parking brake lock and slowly allow ATV

to roll around to your right until ATV is pointing across the hill or slightly down-

ward.

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

weight uphill.

7.Restart engine with transmission still in forward, release parking brake, and pro-

ceed slowly, controlling speed with the service brake, until ATV is on reason-

ably level ground.

WARNING

Avoid climbing steep hills.

Loss of vehicle control or overturning of the ATV could occur.

DUse extreme care when operating your ATV in hilly terrain.

RIDING

Crossing Streams

Your Polaris ATV can operate through water up to depths reaching

the footrests. Before fording streams always:

1.Determine water depths and current.

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

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

4.After crossing, dry the brakes by applying light pressureto the leveruntilbraking

action is normal.

CAUTION: Should your ATV become immersed, it will be necessary to take it to

your dealer as soon as possible. Do not start the engine! Immersion of the ATV

can cause major damage if not correctly repaired.

WARNING

Never try to cross any deep or fast flowing streams.

The large tires can cause the ATV to float resulting in loss of control.

DDetermine stream depth and speed before crossing.

RIDING

Trail Obstacles

Keep Alert!

Look ahead and learn to read the trail as you ride. Stay on the right side of the trail,

ifpossible,and beconstantly alert forhazardssuch as logs, rocks and lowhanging

branches.

WARNING

Hidden or unseen hazards on the trail can be dangerous.

Personal injury or the vehicle overturning can occur from unseen obstacles.

DKeep alert and constantly look for obstacles on the trail.

indicates a potential hazard which

couldresult in serious injury ordeath.

WARNING

RIDING

Backing Up

1.Whenever backing up, always avoid backing downhill.

2.Back slowly.

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

4.Avoid turning at sharp angles in reverse.

5.Never open the throttle suddenly while backing.

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

NOTE: This vehicle is equipped with a reverse speed limiter. The override button

should be used with caution as rearward vehicle speed is greatly increased. Do

not operate at wide open throttle. Only open the throttle enough to maintain a de-

sired speed. Opening the throttle more than required may cause excessive fuel

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

WARNING

Backing your ATV can be dangerous! You could hit an obstacle or person

behind you; or the ATV could tip over rearward on a steep incline.

DAlways back slowly, avoiding excessive speed; and do not use the

reverse speed override switch system unless additional power is

required for vehicle movement.

DAvoid backing on steep inclines.

RIDING

ParkingonanIncline

Whenever the Vehicle is Parked

1.Turn the engine off.

2.Place the transmission in gear.

3.Set the parking brake.

4.Avoid parking on an incline. If it is necessary to park on an incline, always block

the rear wheels on the down hill side as shown above.

5.Shut off fuel supply.

indicates a potential hazard which

couldresult in serious injury ordeath.

WARNING

BATTERY

Battery

CAUTION

Whenever removing the battery, discon-

nect the negative (black) cable first. When

reinstalling the battery, connect the nega-

tive (black) cable last.

Replenishing the Battery Fluid

A poorly maintained battery will deteriorate

rapidly. Check the battery fluid level often.

The fluid level should be kept between the

upper and lower level marks.

To refill use only distilled water. Tap

water contains minerals which are harmful

to a battery.

Battery Connections

Battery terminals and connections should be kept free of corrosion.

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

a solution of one tablespoon baking soda and one cup water. Rinse well with tap

wateranddry offwith clean rags. Coat the terminalswith dielectric grease orpetro-

leum jelly.

Do not allow cleaning solution or tap water to enter the battery. It will shorten

the life of the battery.

WARNING

Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can

result from contact with skin, eyes or clothing. Antidote:

External: Flush with water.

Internal: Drink large quantities of water or milk. Follow with milk of magnesia,

beaten egg, or vegetable oil. Call physician immediately .

Eyes: Flush with water for 15 minutes and get prompt medical attention.

Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away.

Ventilate when charging or using in an enclosed space. Always shield eyes

when working near batteries. KEEP OUT OF REACH OF CHILDREN.

Maintain

between

upper and

lower level

marks

BATTERY

Battery Removal

1.Disconnect hold down straps holding the electrical box and battery in position

and remove battery cover.

2.Remove the battery vent tube from the battery.

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

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

5.Lift the battery out of the ATV, being careful not to tip it sideways and spill any

electrolyte.

CAUTION: If electrolyte spills, immediately wash itoff with a solution of one table-

spoon baking soda and one cup water to prevent damage to the ATV.

Battery Installation

WARNING: To avoid the possibility of explosion, always connect battery cables

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

1.Set the battery in its holder.

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

installed. If not, battery gases could accumulate and cause an explosion. The

tube should be routed away from the frame and body to prevent corrosion.

Avoid skin c ontact with electrolyte, severe burns could result.

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

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

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

6.Verify that cables are properly routed.

NOTE:

DWhen your ATV is placed in storage for three months or more, the battery

should be removed, charged to proper level, and stored in a cool dry place.

DBefore reusing, take the battery to your dealer for testing and recharging.

DPower plug leads may need to be bent down so that the battery cover may be

installed.

NOISE EMISSION CONTROL SYSTEM REGULATION

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED!

U.S. Federal law prohibits the following acts or the causing thereof:

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

maintenance, repair, or replacement of any device or element of design incorpo-

rated into any new vehicle forthepurposeofnoisecontrolpriorto itssaleordelivery

to the ultimate purchaser or while it is in use or

(2)the use of the vehicle after such device or elementof designhas been removed

or rendered inoperative by any person.

“AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE

ACTS LISTED BELOW.”

1.Removal or alteration or the puncturing of the muffler or any engine component

which conducts removal of engine exhaust gases.

2.Removal or alteration or the puncturing of any part of the engine air induction

system.

3.Replacement of any vehicle parts with parts not in compliance with federal regu-

lations.

4.Lack of proper maintenance.

CAUTION: Remember,exhaust systemcomponents are very hot during and after

use of ATV.

DDo not touch exhaust system components. Serious burns can result.

DBe especially careful when traveling through tall grass. The potential for fire

exists.

USFS Approved Spark Arrestor

MostPolaris ATVs have mufflers thatwere testedand approvedinaccordancewith

theUSFS ForestService Standard 5100-1A. Forspecific informationon yourmod-

el, see the Owner’s Manual Specification Supplement that came with your ma-

chine.

MAINTENANCE

Spark Arrestor

The exhaust pipe must be periodically purged of accumulated carbon as follows:

1.Remove the clean out plugs

located on the bottom of the

muffler as shown above.

2.Place the transmission in

neutral and start the en-

gine. Purge accumulated

carbon from the system by

momentarily revving the

engine several times.

3.If some carbon is expelled,

cover the exhaust outlet

and rap on the pipe around

the clean out plugs while

revving the engine several

more times.

4.If particles are still suspected

to be in themuffler, back the

machine onto an incline so

the rear of the machine is

one foot higher than the

front. Set the parking brake

and block the wheels.

Make sure the machine is in

neutral and repeat steps 2

and 3. WARNING: SEE

BELOW.

5.If particles are still suspected

to be in the muffler, drive the

machine onto the incline so

the front of the machine is

one foot higher than the

rear. Set the parking brake

and block the wheels.

Make sure the machine is in

neutral and repeat steps 2

and 3. WARNING: SEE

BELOW.

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

is revved.

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

8.Reinstall the arrestor plugs.

Clean Out Plugs

Clean Out Plug

MAINTENANCE

Spark Arrestor (Cont.)

WARNING

DDo not perform this operation immediately after the engine has been run

because the exhaust system becomes very hot.

DBecause of the increased fire hazard, make sure that there are no com-

bustible materials in the area when purging the spark arrestor.

DWear eye protection.

DDo not stand behind or in front of the vehicle while purging the c arbon

from the spark arrestor.

DNever run the engine in an enclosed area. The exhaust contains poi-

sonous carbon monoxide gas.

DDo not go under the machine while it is inclined.

Fail ur e to heed these war ni ngs could result in ser i ous per sonal injury or death.

CAUTION: Keep combustible materials away from exhaust system. Fire may re-

sult.

MAINTENANCE

Tool Kits

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

compartment under the seat. Items included in the k its are:

2 -cycle engines

Dflat screwdriver

Dspark plug wrench with Phillips head screwdriver

Dwrench

Dtire pressure gauge

Dspanner wrench for adjusting rear shock spring preload (selected models)

4 -cycle engines

Dscrewdriver

Dopen end wrench (8-10 mm)

Dopen end wrench (12-14 mm)

Dbox end wrench

Dtire pressure gauge

Dspark plug wrench and handle

Dspanner wrench for adjusting rear shock spring preload (selected models)

NOTE: Other tools are also necessary to perform maintenance work. They are

called out later in this manual.

Power Pig Tail

Some models are equipped

with an auxiliary power outlet.

Refer to your Owner’s Manual

Supplementto determine ifyour

machine has one.

CAUTION: Be sure to wrap

bare wires with electrical tape

and follow correct wire splicing

procedures to avoid shorts in

the wiring system.

The power outlet and pigtail

may be purchased from Polaris

using the following numbers:

outlet - 2410022; pigtail -

2460442

Power

Outlet

2410022

Pigtail

2460442

Rear Mounted Power Outlet

MAINTENANCE

Periodic Maintenance Schedule

Carefulperiodic maintenancewill help keepyourvehicleinthesafest,mostreliable

condition. Inspection, adjustment and lubrication intervals of important compo-

nents are explained in the following chart

Maintenance intervals are based upon average riding conditions and a vehicle

speed of approximately 10 miles per hour. Vehicles subjected to severe use, such

as operation in wet or dusty areas, should be inspected and serviced more fre-

quently. If you are not familiar with safe service and adjustment procedures, have

a qualified dealer perform these operations.

Inspect, clean, lubricate, adjust or replace parts as necessary. NOTE: Inspection

may reveal the need for replacement parts. Always use genuine Polaris parts

available from your Polaris dealer.

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

adjustment procedures, have a qualified dealer perform these operations.

J CAUTION: Due to the nature of these adjustments, it is recommended that

service be performed by an authorized Polaris dealer. Do not attempt to perform

this work unless you are familiar with mechanical repair.

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

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

models may have an additional California -only emissions warranty. Please refer

to your owner’s manual supplement to determine if this applies to your vehicle.

Item Hours or

Odometer

Frequency Remarks

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

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

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

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

Frame nuts, bolts , fasteners Pre-ride Pre-ride Pre-ride inspection item

Injector Oil Level (2-Cycle) Daily Daily Check when refueling

Air Filter - Pre-Cleaner Daily Daily Inspect-Clean

Coolant/Level Inspection Daily Daily Replace engine coolant every two

years

" Air Box Sediment Tube Daily Daily Drain deposits whenever vi sible

Headlamp Inspection Daily Daily Check operation daily; apply Polaris di -

electric grease to connector when re-

placed

Tail lamp inspection Daily Daily Check operation daily; apply Polaris di -

electric grease to socket when replaced

AirFilter-MainElement Weekly Weekl y Inspect-Replac e if necessary

" Transmission Oil Level 25 hrs Monthly Inspect monthly; change annually

Battery 20 hrs Monthly Check Terminals/cl ean/check fluid level

Engine Counterbalance

(400 Engines)

20 hrs Monthly Check oil level; change annuall y

MAINTENANCE

Periodic Maintenance Schedule (Cont.)

Item Hours or

Odometer

Frequency Remarks

Engine breather filter

(4-cycle)

20 hrs Monthly Inspect --replace annually and as need-

J Brake pad wear 10 hrs/100

miles

Monthly Inspect periodically

" Front and Rear Gearcase Oil

(shaft drive)

100 hrs Monthly Check monthly and change annually

Engine Cylinder Head and

Cylinder Base Fasteners

25 hrs 3 months Inspect (re-torque required at first ser-

vice only)

" General Lubrication 50 hrs 3 months Lubricate al l fittings, piv ots, cables, etc.

Engine Oil - Level/Change

(4-Cycle)

100 hrs/1000

miles

6 months Check Level Daily; Break in Service at

1 month. Change oil more often in c old

weather use.

Oil Filter(4-Cycle) 100 hrs/1000

miles

6 months Replace wi th oil c hange

Oil Pump Cable (2-Cycle) 50 hrs 6 months Inspect, adjust, lubricate, replace if re-

quired

Engine breather hose

(4-cycle)

100 hrs 6 months Inspect

Carburetor Float B o wl 50 hrs 6 months Drain bowl periodically and prior to stor-

age

J Throttle Cable/ETC Switch 50 hrs 6 m onths Inspect--adjust, lubricate, replace if nec-

essary; pre-ride inspection item

Choke (Enricher) Cable 50 hrs 6 months Inspect--adjust, lubricate, replac e if nec-

essary

Coolant strength/pressure test

system

100 hrs 6 months Inspect strength seasonally; pressure

test system annually

" Front hubs/fluid check (AWD) 50 hrs 6 months Check monthly

Shift linkage 50 hrs 6 months Inspect, adjust

J Drive belt 50 hrs 6 months Inspect, replace if necessary

J Steering 50 hrs 6 months Inspect daily, lubricate

" Rear Axle 50 hrs 6 months Inspect bearings, Lube

" Front Suspension 50 hrs 6 months Inspect--lubricate, tighten fasteners

" Rear Suspension 50 hrs 6 months Inspect, tighten fasteners

" Drive Chain(s) 50 hrs 6 months Inspect daily, adjust and l ubricate if

needed

Spark Plug 100 hrs 12 months Inspect-- replace if necessary

Ignition Ti ming 100 hrs 12 months Inspect and adjust as needed

Fuel System 100 hours 12 months Check for leaks at tank c ap, lines, fuel

valv e, filter, pump and carburetor. Re-

place lines every two years.

J Fuel Filter 100 hrs 12 months Repl ace annuall y

Radiator 100 hrs 12 months Inspect/clean external surface

Cooling System hoses 100 hrs 12 months Inspect

Spark arrestor 100 hrs 12 months Clean out

MAINTENANCE

Periodic Maintenance Schedule (Cont.)

Item Hours or

Odometer

Frequency Remarks

" Front hubs/fluid change (AWD) 100 hrs 12 months

J Clutches (drive and driven) 100 hrs 12 months Inspect, clean

Engine Mounts 100 hrs 12 months Inspect

Valve Clearance (4-Cyc le) 100 hrs 12 months Inspect/A djust

Spark Plug 100 hrs 12 months Inspect-- replace if necessary

Ignition Ti ming 100 hrs 12 months Inspect and adjust as needed

J Fuel Filter 100 hrs 12 months Replac e annually

Radiator 100 hrs 12 months Inspect/clean external surface

Cooling System hoses 100 hrs 12 months Inspect

Spark arrestor 100 hrs 12 months Clean out

" Front hubs/fluid change (AWD) 100 hrs 12 months

J Clutches (drive and driven) 100 hrs 12 months Inspect, clean

Fuel System 100 hours 12 months Check for leaks at tank c ap, lines, fuel

valv e, filter, pump and carburetor. Re-

place lines every two y ears.

J Injector Oil Filter (2-Cycle) 100 hrs Annually Replace

J Shift selector box (H/L/R) 200 hrs 24 months Change lubricant every two years

J Brake fluid 200 hrs 24 months Change every two years

J Front wheel bearings (2wd) 300 hrs 36 months Inspect, replace if neces sary

Idle Speed As Required As Required Adjust

Recoil housing As required As required Drain moi sture out after riding in water

J Toe adjustment As required As required Periodic inspection, adj ust when parts

are replaced

Headlight A im As required As required Adjust if necessary

J CAUTION: Due to the nature of these adjustments, it is recommended that

service be performed by an authorized Polaris dealer. Do not attempt to perform

this work unless you are familiar with mechanical repair.

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

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

NOTE: Some 4-Cycle models may have an additional California -only emissions

warranty. Please refer to your owner’s manual supplement to determine if this ap-

plies to your vehicle.

MAINTENANCE

Lubrication Recommendations

Item Lube Rec. Method Frequency*

1. Engine Oil

(2-Cycle)

Polaris

Injection Oil

Fill oil tank. See page 47. As needed,

when refueling

2.Engine Oil

(4-Cycle)

Polaris Pre-

mium 4 Syn-

thetic 0W40

Add to proper level on dipstick.

See page 49.

Check level dai-

ly .

3. Brake Fluid DOT 3 Only Maintain level between fill lines.

See page 39.

As required;

change every

two years or 200

hours

4. Transmission

Oil

Polaris Pre-

mium Syn-

thetic gear

case lube

Add to FULL level on dipstick or

fill to bottom of the filler hole,

whichever is applicable.

Change annually

or at 100 hours

5. Front Gear-

case Oil

GL 80-90

Weight Gear

Lube

Fill to bottom thread of filler hole.

Make certain machine is on level

surface.

Change annually

or at 100 hours

6. Front Prop

Shaft U-joints

Grease+ Locate Fittings and Grease Every 3 months

or 50 hours

7. Front Prop-

shaft Yoke

Grease+ Locate fittings and grease -- 3

pumps maximum

Every 3 months

or 50 hours

8. Drive Chain(s) O-Ring chain

lube or

SAE 80/90

Lubricate as often as required.

Before each ride in wet conditions

As required

9. Demand 4

Hubs - All

Wheel Drive

ATVs

Premium

Hub Lube

Remove set screw in hubs. Ro-

tate wheels to 4 O’clock position.

If lubricant is not visible add more.

Reinstall set screw.

Annually or at

100 hrs

10. Front Drive

Axle (U Joint)

(AWD Mod

els)

Grease+ Locate grease fitting and grease

with grease gun.

Every 3 months

or 50 hours

11. Ball Joint Grease** Locate fitting on back side of

struts and grease with grease

gun.

Every 3 months

or 50 hours

12. Rear Gear

Case

GL 80-90

Weight Gear

Lube

Fill to bottom of the fill hole. Change annually

or at 100 hours

MAINTENANCE

Lubrication Recommendations

13. Front A Arm

Pivot Shaft

Grease**∆ Locate fitting on pivot shaft and

grease with grease gun.

Every 3

months or 50

hours

14. Counter Bal-

ance Housing

(400)

SAE 10/30 Check level on dipstick and add oil as

necessary. Change annually. To

change oil see page 108.

Check month-

ly and change

annually

15. Steering Post

Bushings

Grease** Locate fittings on steering post and

grease with grease gun.

Every 3

months or 50

hours

16. Rear Axle

Bearing

Grease** Locate fittings and grease Every 3

months or 50

hours

17. Swing Arm

Bushings

Grease** Locate fittings on swing arm and

grease with grease gun.

Monthly or at

20 hours

18. Upper Control

Arms

Grease**∆ Locate fittings and grease Semi-annually

19. Lower Control

Arms

Grease**∆ Locate fittings and grease Semi-annually

20. Rear Wheel

Hub Bearing Car-

rier

Grease**∆ Locate fitting and grease Semi-annually

21. Rear Anti-Roll

Bar

Grease Locate fitting and grease Semi-annually

* More often under severe use, such as wet or dusty conditions.

**Polaris Premium all Season Grease or grease conforming to NLGI No. 2, such as

Conoco Superlube M or Mobilegrease Special.

+ Grease every 500 miles, or after submerging in water or before long periods of storage or

after pressure washing. Always use Polaris Premium U-Joint Lube for maximum service of

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

∆ When suspension action becomes stiff or after washing.

NOTE: Hours are based on 10 mph average.

MAINTENANCE

Lubrication Recommendations

Operating

Range

Full

4. Transmission

(dipstick)

6. Front Prop Shaft

(U-Joint)

10. Axle Cardan

Front Drive

(AWD Models)

7. Propshaft Yoke

Fill plug

5. Front Gear Case

14. Counterbalance

Dipstick

4. Transmission

(plug)

12. Rear Gear

Case - Fill Hole

MAINTENANCE

Lubrication Recommendations

15. Steering Post Bushings

11. Ball Joint

13. Front A-Arm

Pivot Shaft

Lower

Upper

9. 4 O’clock

position

9. Demand 4 Hubs

(4x4 only)

MAINTENANCE

Lubrication Recommendations

17. Swing Arm Bushings

16. Rear Axle Bearing

18. Upper Control

Arm

20. Rear Wheel

Hub Bearing

Carrier

21. Rear Anti-

Roll Bar

19. Lower Control

Arm

INDEPENDENT REAR SUSPENSION

19. Lower Control

Arm

MAINTENANCE

Periodic Maintenance Record

Use the following chart to record periodic maintenance work:

Maintenance

Interval

Performed

Servicing

Date

Servicing

Dealer

or Person

Remarks

First 5 Hrs.

25 Hrs.

50 Hrs.

75 Hrs.

100 Hrs.

MAINTENANCE

Steering

Handlebar Adjustment

Your ATV has handlebars which can

be adjusted for your personal fit.

1.Locate handlebar bolts. On mod-

els with a headlight pod, it will be

necessary to remove the upper

headlight pod. On other models

remove the handlebar cover.

2.Loosen the four bolts.

3.Adjust handlebarto desiredheight.

Be sure handlebars do not hitgas

tank or any other part of machine

when turned fully to left or right.

4.Torque handlebar adjuster block

bolts to 10 to 12 ft. lbs.

NOTE: Tighten bolts so there is an

equal gap at the front and rear of the

handlebar block. Improper gap will

result in improper fit of upper pod.

W ARNING

Improper adjustment of the handlebars or incorrect torquing of the adjuster block

tightening bolts cancause limited steeringorlooseningofthehandlebars,resulting

in loss of control and possible serious personal injury or death.

MAINTENANCE

The following items should be checked occasionally for tightness; or if they have

been loosened for maintenance service.

Axle and Wheel Nut Torque Specifications

Model Item Specification

Front Spindle Nut(s) 40 Ft. Lbs.

Front Wheel Nuts 15 Ft. Lbs.

Rear Axle Nut(s) 80 Ft. Lbs.

Rear Wheel Nuts 50 Ft. Lbs.

Front Spindle Nut(s) Dealer Performed Service

Front Wheel Nuts 15 Ft. Lbs.

Chain Drive

Rear Axle Nut(s) 80 Ft. Lbs.

Rear Wheel Nuts 50 Ft. Lbs.

Front Spindle Nut(s) Dealer Performed Service

Front Wheel Nuts 15 Ft. Lbs.

Shaft Drive

Rear Hub Retaining Nut(s) 100 Ft. Lbs.

Rear Wheel Nuts 50 Ft. Lbs.

Front Wheel Hub Tightening

Frontwheel bearing tightness and spindle nut retention are critical component op-

erations. Service work must be performed by your authorized Polaris dealer.

MAINTENANCE

Rear Spring Adjustment

The rear shock absorber spring is adjusted by rotating the adjuster in the direction

required to increase or decrease spring tension.

Rear Spring

Adjustment

Cam

Rear Spring

Adjustment

Cam

Rear Spring

Adjustment

MAINTENANCE

Side Panel Removal (Gen IV Models)

Side panel removal may be difficult until the locking tabs and receivers have been

snapped and unsnapped a few times.

1. Remove seat. Grasp rear

ofside panel near rearcab.

With a quick and firm

motion, pull the panel

forward and outward to

disengage the two rear

tabs.

2. Place hand on top of side

panel behind the fuel tank.

With a quick and firm

motion, push down on the

side panel to disengage

thetoprear two tabs. Then

pull up on side panel to

disengage front upper and

lower tab.

3. To reinstall side panel,

align panel tabs with slots

on front cab. Push panel

upward and forward until

tabs lock. Bend rear of

side panel and insert the

two tabs into the rear cab.

Pull forward and out to disengage

two rear tabs.

Step 1.

Push down to disengage top rear

two tabs.

Step 2.

To reinstall, align panel tabs with

slots. Push upward and forward un-

til tabs lock.

Step 3.

MAINTENANCE

Air Cleaner

Trail Blazer

Secondary (Main) Filter

Inspect the secondary filter weekly or after every 50 hours of operation.

CAUTION: Never operate the ATV with the filter element removed. Dirt will enter

the engine causing serious rapid wear and damage to the engine.

Secondary filter removal and installation procedure:

1.Remove ATV seat.

2.Remove primary air filter box.

3.Removefourwing nutsholdingcover

assembly to secondary air filter

housing.

4.Remove filter element.

5.Inspect gaskets on both sides of fil-

ter. Replace if required.

6.Coat top and bottom gaskets of filter

with a generous amount of grease.

7.Check condition of air box and replace if necessary. Install filter into airbox. Be

sure filter element seats securely.

8.Check cover gasket and replace if required. Be sure cover is seated properly

and wing nuts are finger tightened securely.

9.Reinstall primary air filter box as per instructions found on page 93.

10.Reinstall ATV seat.

Cleaning the Main Filter

Important:

It is advisable to replace the filter when it is dirty. However, in an emergency it is

permissible to clean the main filter if you observe the following practices.

1.Never immersethefilter in watersince dirtcanbe transferred to thecleanairside

of the filter.

2.If compressed air is used never exceed a pressure of 40 PSI. Always use a dis-

persion type nozzle to prevent filter damage and clean from the outside to the

inside.

NOTE: Replace the air filter every 50 hours, and possibly more often in very dirty

conditions.

MAINTENANCE

Air Filter Service

Trail Blazer

1.Release seat latch and lift up on

the rear of the seat and remove

seat.

2.Remove the primary air filter box.

3.Remove the yellow pre-cleaner

foam boot, held in place by a

gray collar, from the air box.

4.Carefully wash the yellow foam

boot in soapy water and dry it.

5.Oil the foam boot with engine in-

jection oil (1 to 2 teaspoons).

Squeeze out the excess into an

absorbant cloth.

6.Reinstall the yellow foam boot

and gray collar onto the air filter

box.

7.Reinstall the primary air filter box

removedinstep2.NOTE:

There will be some resistance.

Be sure the black rubber seal-

ing ring is securely positioned

over the main filter neck.

CAUTION: When installing the pri-

mary air filter box be sure the gray

foam collar (B) is below the intake

opening of the air box intake (A).

Improper installation will restrict air-

flow to theengine possibly resulting

in engine damage.

Gray Collar

Yellow Boot

Intake Silencer

Airbox

Air Filter

Airbox Retainer

Airbox Cover

Main Filter Neck

MAINTENANCE

Air Filter Service

Scrambler 500

1.Remove seat.

2.Release clips and remove cover.

3.Loosen clamp and remove filter

4.Removefabric type pre-filter from

main filter. Wash pre-filter in

soapy water and dry it.

5.Reinstall pre-filter over mainfilter.

Replace main filter as required.

6.Reinstall filter into air Box and

tighten clamp. Do not overtight-

en clamp or filter damage may

occur.

Main Filter

Pre-Filter

MAINTENANCE

Air Filter Service - Sportsman 500, Scrambler 500

1.Remove seat.

2.Remove spring

clampssecuringthe

airbox lid and re-

move lid.

3.Loosen clamp and

remove filter

4.Remove fabric type

pre-filter from main

filter. Wash pre-filter

in soapy water and

dry it.

5.Reinstall pre-filter

over main filter. Re-

place main filter as

required.

6.Reinstall filter into air

Box and tighten

clamp. Do not over

tighten clamp or fil-

terdamage may oc-

cur.

CAUTION: Operation of your ATV without a breather filter can c ause engine dam-

age.

Breather Filter and Hose - Sportsman 500, Magnum 500,

Scrambler 500

1. Remove the clamps and pull

the filter out of the hoses.

NOTE: It will not

necessary to remove the

lower hose from the engine.

2. Inspect filter for debris. Blow

through gently in direction of

arrow on filter to check for

clogging. Replace as

needed.

3. Check hoses for cracks,

deterioration, abrasion, or

leaks. Replace as needed.

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

Main Filter

Pre--filter

Breather

Filter

MAINTENANCE

Steering Inspection

The steering assembly of the machine should be checked periodically for loose

nuts and bolts. If loose nuts and bolts are found, have your dealer tighten them

before riding your vehicle.

Camber and Caster

The camber and caster are non-adjustable.

Toe Alignment

You can check the toe align-

ment of the vehicleusing the fol-

lowing method. The recom-

mended toe alignment is 1/8″ to

1/4″ (.3to.6cm)toeout. Ifyou

discover improper adjustment

have your dealer correct it.

1.Set the handlebars in a

straight ahead position and

hold them in this position.

NOTE: The steering frog

can be used as an indicator

of whether the handlebars

arestraight. The frog should

always point straight back

from the s teering post.

2.Place stands in front of the

machine, perpendicular to

the rear tires.

3.Tie an elastic string around

the machine, making sure

string just touches side sur-

face of the rear tires on each

side of machine and goes

around the stands in front of

the machine.

4.Measure from string to rim at

front and rear of front rim.

Rear rim measurement

should be 1/16″ -1/8″ (.2 to

.3 cm) more than front rim

measurement.

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

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

injury or death can result from improper adjustment. Contact your Polaris dealer.

He/she has the training and tools to make these adjustments.

MAINTENANCE

Front Brake

The front brakes are hydraulic disc type brakes which are activated by the brake

lever being moved toward the handlebar. These brakes are self-adjusting and re-

quire no adjustment.

The following checks are recommended to keep the brake system in good operat-

ing condition. How often they need checking depends upon the typeof drivingthat

has been done.

DKeep fluid level in the master cylinder reservoirs between the max and min

level marks at all times. Normal functioning of the diaphragm is to extend

into the reservoir as fluid level drops. If the fluid level is low and the dia-

phragm is not extended, a leak is indicated and the diaphragm should be

replaced. Always fill the reservoir as indicated whenever the cover is loos-

ened or removed to insure proper diaphragm operation. Use Polaris DOT 3

brake fluid (PN 2870990).

WARNING: Once a bottle of brake fluid is opened, use what is necessary and dis-

card the rest. Do not store or use a partialbottle of brake fluid. Brakefluid is hygro-

scopic, meaning it rapidly absorbs moisture from the air. This causes the boiling

temperature of the brake fluid to drop, which can lead to early brake fade and the

possibility of serious injury.

DCheck brake system for fluid

leaks.

DCheck brake for excessive travel

or spongy feel.

DCheck friction pads for wear, dam-

age and looseness.

DCheck security and surface condi-

tion of the disc.

DPads should be changed when

worn to 3/64″ (.1 cm), or about

the thickness of a dime.

3/64″ (.1 cm)

MAINTENANCE

Rear and Auxiliary Brake

Rear Brake

The rear brake is a hydraulic disc

type brake which is activated by the

same lever which activates the front

brake system. The rear brake sys-

tem is self adjusting and requires no

maintenance other than periodic

checks of the pads for wear.

DPads should be changed when

worn to 3/64″ (.1cm)whichis

about the thickness of a dime.

DInspect the brake disc spline and

pad wear surface for excessive

wear.

Auxiliary Brake Systems

Your ATV’s auxiliary brake system is intended to be used as a backup for the main

brake system. Should the main system fail, the rear brake can be activated by de-

pressing the foot pedal on the inside of the right floorboard. All Polaris ATVs have

hydraulic brake systems. The hydraulic auxiliary brake system will not require ad-

justment.

NOTE: Since this is a rearbrake only,it will not be as effective as the all wheel sys-

tem.

3/64″ (.1 cm)

MAINTENANCE

Oil Pump Adjustment Procedure

400 Engines

1.Before adjusting the oil pump, check

engine idle RPM and carburetor ad-

justments which are found in the own-

er’s manual supplement.

2.Loosen throttle cable jam nut and turn

adjuster in or out until there is 1/16″ -

1/8″ (.16 - .32cm) ofthrottle levertrav-

el before throttle slide starts to open.

See Owner’s Manual Supplement.

3.Place very slight pressure on the

throttle lever until all freeplay is re-

moved from throttle cable (to the point where the carb slide is just starting to

rise).

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

adjuster locknut. Adjust oil pump cable until marks align (D) when the throttle

slide just begins to raise.

5.Tighten the locknut.

6.Recheck adjustment. If correct, slide boot all the way down over the upper por-

tion of the bottom nut to ensure good sealing against water entry. Reinstall oil

pump cover and gasket.

Oil Pump Adjustment 400

Boot

Adjuster

Sleeve

Upper Portion

of Bottom Nut

100

MAINTENANCE

Oil Pump Adjustment Procedure

250 Engines

1.Before adjusting the oil pump,

check engine idle RPM and car-

buretor adjustments which are

found in the owner’s manual sup-

plement.

2.Loosen throttle cable jam nut and

turn adjusterin or out until there is

1/16″ -1/8″ (.16 - .32 cm) of

throttle lever travel before throttle

slide starts to open. See Owner’s

Manual Supplement.

3.Place very s light pressure on the

throttle leveruntil allfreeplay is re-

moved from throttle cable (to the

point where the carb slide is just

starting to rise).

4.Loosen locknut. Turnadjuster inor

out until all freeplay is removed

from oil pump cable (the point

where the oil pump arm is just

starting to move off of its stop).

The pump stop keeps the pump

arm from rotating any farther

down than the idle position so no

visual alignment of marks is nec-

essary. Tighten the locknut

Oil Pump Bleeding Procedure

1.Fill the oil reservoir with Polaris injector oil.

2.Loosening the bleederscrew is onlynecessary when theoilsupplyline hasbeen

disconnected from the pump or the oil reservoir and supply line have been

completely run out of oil. In these cases, loosen the pump bleed screw one full

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

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

Loss of oil will cause serious engine damage.

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

engine at idle, hold the lever up for thirty seconds to make sure all air is out of

the system.

Lever

Locknut

Cable Adjuster

Locknut

Lever Arm

101

MAINTENANCE

Throttle Cable Adjustment

250 and 400 Engines

Vehicles with 250 and 400 engines do not utilize a cable sleeve jam nut. You will

need to bottom the cable to the carburetor slidevalve cap. Adjust at throttle cable

adjuster near the throttle block.

Engine Choke Adjustment

2-Cycle Engines

With the dash mounted choke control toggle flipped to full off position, the c hoke

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

isnot seated on the passageway, the engine willflood orruntoorich,causingspark

plug fouling and very poor engine performance.

If there is too much choke cable slack resulting in excessive toggle free play, the

enginewillbe hardstarting when cold and the half-on choke position used forinter-

mittent applications will not function.

Choke Adjustment Procedure

1.Flip choke toggle to the full off posi-

tion.

2.Loosen adjustment locknut (A) on

carburetor.

3.Turn cable sleeve adjusting nut (B)

clockwise on carburetor until 1/8″

(.3 cm) or more choke toggle free

play is evident.

4.Turn the cable sleeve adjusting nut

counterclockwise on the carbure-

tor until the toggle has zero free

play. Then rotate it clockwise until

1/8″ to 1/4″ (.3 to .6cm) toggle free

play is evident.

5.Tighten adjustment locknut.

1/8I-1/4I Freeplay

(.3-.6 cm)

Choke Top View

102

MAINTENANCE

Carburetor/Engine Idle RPM Adjustment

2 Cycle Engines

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

the c arburetor can be adjusted as follows:

1.Warm up the engine by running

the vehicle approximately five

minutes.

2.Place the transmission in gear

with the parking brake applied.

3.Adjust the carburetor idle screw

in or out until the desired idle

RPM is reached . Turning the

screw in (clockwise) will raise

RPM. Turning the screw out

(counterclockwise) will lower

RPM.

The following variations to air screw adjustment for 2-Cycle engines should be

noted:

DFor improving cold weather start and reducing audible detonation noise, the

air screw can be closed from 1/2 to 1 turn by turning the screw clockwise.

DDuring hot weather and/or high altitude operation the air screw can be ad-

justed for smooth operation by approximately 2 turns counterclockwise.

Choke Adjustment Procedure

4-cycle Engines

1.Flip choke toggle to the full off posi-

tion.

2.Slide boot off in-line cable adjuster

sleeve. Loosen adjustment lock-

nut on in-line cable adjuster.

3.Turn cable sleeve adjusting nut

clockwise on in-line adjuster until

1/8″ (.3 cm) or more choke toggle

free play is evident.

4.Turn the cable sleeve adjusting nut

counterclockwise on the in-line

cable adjuster until the toggle has

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

free play is evident.

5.Tighten adjustment locknut.

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

of the sleeve.

Idle

Screw

Air Screw

1/8I-1/4I Freeplay

(.3-.6 cm)

Choke Top View

103

MAINTENANCE

Carburetor/Engine Idle RPM Adjustment

4 -cycle Engines

If the engine idle speed is not satis-

factory, and all other conditions are

favorable, the carburetor can be ad-

justed as follows:

1.Warm up the engineby runningthe

vehicle approximately five min-

utes.

2.Place the transmission in gear with

the parking brake applied.

3.Adjust the carburetor idle screw in

oroutuntilthe desiredidle RPMis

reached. Turning the screw in

(clockwise) will raise RPM. Turn-

ing the screw out (counterclock-

wise) will lower RPM.

Throttle Cable Free Play Adjustment

Throttle cable free play is adjusted at the handlebar.

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

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

3.Tighten locknutand slide boots over cable adjuster untilthey touch at the middle

point of adjuster.

Idle Screw

Boot

Adjuster

Sleeve

Locknut

Boot

104

MAINTENANCE

Spark Plugs

Check your owner’s manual supplement for recommended spark plug and gap.

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

firing end condition should be read after the engine is warmed up and the vehicle

is driven at higher speeds. Immediately check the spark plug for correct color.

1. Normal

The insulator tip is gray, tan or light brown. There will be few combustion deposits.

The electrodes are not burned or eroded. This indicates the proper type and heat

range for the engine and the service.

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

caused by use of an improper spark plug or incorrect carburetion adjustments.

2. Wet Fouled

The insulator tip is black. A damp oil film covers the firing end. There may be a

carbon layerover theentire nose. Generally,the electrodes are notworn. General

causes are excessive oil, use of non-recommended injection oil, improper use of

the choke, or incorrect carburetion adjustments.

Spark Plug Removal and Replacement

WARNING: Never attemptto remove a spark plug while the engine is warm.

The exhaust system or engine could burn you causing severe injury.

The spark plug is removed by using the special wrench provided in the tool pouch.

Remove the spark plug cap and then the spark plug by rotating counterclockwise.

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

Never deviate from the recommended spark plug as engine damage can occur.

Cylinder Head/Cylinder Base Fastener Torque

(2-Cycle Models)

Have your dealer check the ATV cylinder head and cylinder base fasteners for

proper torque at the first service or after 25 hours.

105

MAINTENANCE

Transmission Lubrication - Models with Fill Plug

Scrambler 400, Scrambler 500, Xplorer 400

The transmission fill plug is located on the right side of the machine behind the

propshaft shield or footwell.

The transmissionlubric ant levelshould be checked everysix monthsor 1000 miles

(1600 km), whichever comes first. Transmission oil should be changed annually.

With the ATV on a level surface, remove fill plug and check the lubricantlevel. Lu-

bricant level is correct when it reaches the bottom of the filler hole. The correct

transmission lubricant to use is Polaris Premium Synthetic Gearcase Lubricant

(PN 2871478).

Transmission Oil Changing Procedure

1.Remove propshaft shield from the right side of the vehicle. (on the Xplorer 400,

remove the four screws on the footwell and gently pull outward for access)

2.Remove fill plug.

3.Remove transmission drain plug located on the bottom left hand side and drain

the oil. Catch and discard used oil properly.

4.Clean and reinstall the drain plug.

5.AddPolaris PremiumSynthetic Gearcase Lubricant(PN2871478 -12 oz.bottle)

until oil reaches the bottom of the filler hole.

6.Check for leaks.

7.Reinstall propshaft shield or footwell and screws removed in step 1.

Transmission Fill Plug

106

MAINTENANCE

Transmission Lubrication - Models with Dipstick

Transmission Dipstick

For most models, transmission dipstick is located on the right side of the machine.

On the Sportsman, the dipstick is located near the rear brake disc.

The transmission lubricant level should be checked monthly or 1000 miles (1600

km), whichever comes first. Transmission oil should be changed annually. With

the ATV on a level surface, remove fill plug dipstick and check the lubricant level.

Lubricant should be kept at the full mark on the dipstick. The correct transmission

lubricant to use is Polaris Premium Synthetic Gearcase Lubricant (PN 2871478).

T ransmission Oil Changing

Procedure

1.Remove skid plate if required.

2.Remove fill plug/dipstick.

3.Remove transmission drain

plug side and drain the oil.

Catch and discard used oil

properly.

4.Clean and reinstall the drain

plug.

5.Add Polaris Premium Synthetic

Gearcase Lubricant (PN

2871478 - 12 oz. bottle) to full

mark on the fill plug/dipstick.

6.Check for leaks.

7.Reinstall skid plate removed in

step 1.

Full

Operating

Range

107

MAINTENANCE

Front Gearcase Lubrication

The front gearcase fill plug is located as

shown.

The front gearcase lubricant level

should be checked every six months or

1000 miles (1600 km), whichever

comes first. Front gearcase oil should

be changed annually. With the ATV on

a level surface, remove fill plug and

check the lubricant level. Lubricant

should be kept at the bottom of fill plug

thread. The correct gearcase lubricant

to use is GL5 80-90 Weight Gear Lube.

Gearcase Oil Changing Procedure

1.Remove fill plug.

2.Removegearcasedrain pluglocated on thebottom righthand sideand drainthe

oil.

3.Clean and reinstall the drain plug and tighten securely (14 ft. lbs/1.93 kgm).

4.Add GL 80-90 Weight Gear Lube to the bottom thread on the fill hole.

5.Reinstall filler plug.

6.Check for leaks.

Rear Gearcase Lubrication

With theATV on alevel surface,remove

fillplugand visuallyinspectthelubricant

level. Lubricant should be k ept even

with the center of the drillpoint. NOTE:

Do not add lubricant to the bottom of the

fill plug threads. The correct gearcase

lubricant to use is GL5 80-90 Weight

Gear Lube.

Oil Changing Procedure

1.Remove drain plug. Catch and dis-

card used oil properly.

2.Clean and reinstallthedrain plugwith a new sealing washerand tightensecurely

(14 ft. lbs./1.93 kgm).

3.Remove fill plug and add 300 ml of GL5 80-90 Weight gear Lube and inspectoil

level. Oil level should be kept even with the center of the drill point.

4.Reinstall the fill plug. Tighten securely (14 ft. lbs/1.93 kgm).

5.Check for leaks

Fill plug

Fill Hole

Oil level should be

maintained at the

bottom of the fill

hole.

108

MAINTENANCE

Counter Balance Lubrication

400 Engines

The counter balance oil should be

checked semi-annually and oil

should be added or changed as

necessary. The oil should be

changed annually, especially be-

fore off season storage. If the ma-

chine is used in wet conditions the

oil should be checked more fre-

quently. If the oil has a milky ap-

pearance it should be changed as

soon as possible. Failure to prop-

erly maintain this important area

can result in premature wear or

possible failure of the counter bal-

ance components. Always use

SAE 10W30 oil.

Procedure for Adding Oil

1.Remove seat and locate dipstick.

2.Remove dipstick. Oillevel is shown

on dipstick.

3.AddSAE 10W30oilwithatransmis-

sion fluid funnel until oil is at the

proper level on the dipstick. If

overfilled, excess oil will be ex-

pelled through the vent hose.

4.Reinstall dipstick.

Counter Balance Oil Changing

Procedure

1.Remove skid plate.

2.Remove counter balance drain

plug. Catch used oil and discard

of properly.

3.Clean and reinstall drain plug.

4.Add 10W30 oil to full mark on dip-

stick. Capacity after draining is

approximately 70-75 cc (2.3 - 2.5

oz.).

5.Reinstall dipstick and check for

leaks.

Recoil

Drain

Crankcase Drain

Starter

Pinion Drain

Counter

Balance

Drain

Dipstick

Recommended oil level

Capacity after draining is

approximately 70 - 75cc

Screw dipstick in completely then

remove to check level.

Level

109

MAINTENANCE

Wheel Removal Procedure

1.Stop the engine, place the transmission in gear and lock the parking brake.

2.Loosen the wheel nuts slightly.

3.Elevate the side of the vehicle by placing a suitable stand under the footrest

frame.

4.Remove the wheel nuts and remove the wheel.

Wheel Installation

1.With the transmission in gear and the parking brake locked, place the wheel in

the correct position on the wheelhub. Be sure the valvestem is toward theout-

side and rotation arrows on the tire point toward forward rotation.

2.Attach the wheel nuts and finger

tighten them.

3.Lower the vehicle to the ground.

4.Securely tighten thewheelnutsac-

cording to the chart found on

page 89:

CAUTION: If wheels are improperly

installed it could affect vehicle han-

dling and tire wear.

110

MAINTENANCE

Tire Inspection

CAUTION: Maintain proper tire pressure according to charts below. Improper tire

inflation may affect ATV maneuverability.

When replacing a tire always use original equipment size and type.

CAUTION: The use of non-standard size or type tires may affect ATV handling.

Tire T read Depth

Always replace tires when tread depth is worn to 1/8″ (.3 cm) or less. Please refer

to your Owner’s Manual Supplement for tire specifications.

WARNING

Operating your ATV with worn tires will increase the possibility of the ve-

hicle skidding easily with possible loss of control.

Worn tires can cause an accident.

Always replace tires when the tread depth measures 1/8″ (.3 cm) or less.

Minimum

Tread

Depth 1/8I

(.3 cm)

111

MAINTENANCE

Drive Chain Inspection and Adjustment

Polaris ATV drive chains are equipped with O-ring sealed permanently greased

pins and rollers. However, it is still necessary to lubricate the outer surfaces of the

roller.

CAUTION: Never wash the chain with a high pressure washer or gasoline. Dam-

age to the O-rings will result, causing premature wear and drive chain failure.

Always inspect the drive chain prior to operating the vehicle, checking for dam-

aged or missing O-rings, rollers and correct slack adjustment. Maintain the stone

guard to rear sprocket clearance at 1/8″ (.3 cm).

Regularly lubric ate the drive chain with SAE 80-90 lube or an approved O-ring

chain spray lube.

112

MAINTENANCE

Rear Drive Chain Slack Adjustment

(Models with Concentric Drive)

CAUTION: Never adjust or operate the vehicle with the rear drive chain too

looseortoo tight as severe damageto thetransmission and drive components can

result.

Check the amount of chain slack by moving the vehicle slightly forward to gain

slackat the top side oftherearchain. Atthis pointthe chainshouldhave3/16″-3/8″

(.48 cm-.95 cm) deflection. Ifthe chain needs adjustment,usethefollowingproce-

dure.

Adjustment Procedure

1.Loosen chain guide.

2.Loosen two eccentric locking bolts.

3.Loosen caliper mount bolts.

4.Insert a pin punch through the

sprocket hub and into the eccentric

axle housing.

5.Roll the vehicle ahead or back to ad-

just chain slack to the proper di-

mension.

6.Tighten caliper mount bolts 10-12 ft.

lbs. (1.4 - 1.7 kg/m)

7.Tighten the eccentric locking bolts to

60 ft. lbs. (8.3 kg/m).

8.Reinstall chain guard.

NOTE: Reposition c hain guide to allow

1/8″ (.3 cm)clearance betweensprock-

et and guide.

Rear Drive Chain Adjustment

Proper Splice-

link Clip Open-

ing Position

3/16″-3/8″ (.48 cm - .95 cm) Deflection

113

MAINTENANCE

Headlight Lamp Replacement

WARNING: Due to the nature of ATVs and where they are ridden, headlight

and taillight lenses become dirty. Frequent washing is necessary to maintain light-

ing quality. Poor lighting while riding can result in severe injury or death.

CAUTION: Do not service while headlight is hot. Serious burns may result.

NOTE: Do not touch a halogen lamp with bare fingers. Oil from your skin leaves

a residue, causing a hot spot which will shorten the life of the lamp.

Headlight Lamp Replacement - Scrambler

1.Remove wire harness connector from the back of headlight.

2.Grasp bulb housing, turn counterclockwise and remove bulb.

3.Install bulb into headlight housing and rotate clockwise firmly. NOTE: Bulb is

to be positioned so the harness installs into the lamp at the bottom.

4.Reinstall connector.

High Beam Headlight Adjustment

The headlight beam can be adjusted up and down.

1.Place the vehicle on a level surface with the headlight approximately 25’ (7.6 m)

from a wall.

2.Measure the distance from the floor to the center of the headlight and make a

mark on the wall at the same height.

3.Start the engine and turn the headlight switch to high beam.

4.Observ e headlight aim. The most intense part of the headlight beam should be

aimed 2″ (5.1 cm) below the mark placed on the wall in step 2. NOTE: Rider

weight must be included on the seat.

5.Loosen pivot bolt and adjust beam to desired position.

6.Tighten nut and bolt. Torque to 60 in. lbs.

114

MAINTENANCE

Headlight Lamp Replacement

Trail Blazer, Sport

1.Remove front cover and unplug the light harness.

2.Remove rubber cap from back of headlight to reveal retention screw.

3.Remove small phillips head screw, and carefully remove bulb from housing.

4.Insert new bulb into housing and tighten retention screw, install rubber cap.

5.Reconnect light harness.

6.Install cover to machine.

7.Properly adjust headlight aim.

Headlight Adjustment

1.Place the vehicle on

a level surface with

the headlight

approximately 25’

(7.6 m) from a wall.

2.Measure the dis-

tance from the floor

to the center of the

headlight and make

amarkonthewall

at the same height.

3.Start the engine and

turn on headlight.

4.Observ e headlight

aim. The most in-

tense part of the

headlight beam

should be aimed 8″ (20.3 cm) below the mark placed on the wall in step 2.

NOTE: Rider weight must be included on the seat.

5.Adjustbeam to desired positionby turning adjustmentscrewsin headlight cover.

Turning right screw clockwise moves the intense spot of light up to the left.

Turning the left screw clockwise moves intense spot of light up to the right.

Turning the bottom screw clockwise adjusts the light upwards.

Headlight

adjustment

Screws

Headlight

adjustment

Screw

115

MAINTENANCE

Headlight Lamp Replacement

Trail Boss

1.Remove the seat.

2.Remove the plastic panel surround-

ing the upper portion of the gas tank

by first removing the gas tank cap.

3.Remove the Phillips head screws on

either side of the panel at the junc-

tion of this panel, the lower panels,

and the rear of the front fenders.

4.Remove the Phillips head screws on

either side of the rear of the upper

panelwhich were revealed by the re-

moval of the seat.

5.Disengage the tabs at the front of the

upper panel where they snap into

the lower panel surrounding the

headlight assembly. Alsodisengage

the tabs on the upper panel which

engage with the lower triangular

panelson either side of the machine.

Lift off the upper panel and set it

aside.

6.Reinstall the gas tank cap.

7.Remove the panel surrounding the

headlight by removing the Phillips

head machine screws from either

side of this panel. Also remove the

two Torx screws at the rear of this

panel.

8.Ease the panel forward and up to al-

low you to reach the socket con-

nected to the headlight lamp.

3. & 4.

116

MAINTENANCE

Headlight Replacement (cont.)

9.Carefully unplug the socket from the lamp. Remove the panel and set it aside.

10.Stand the panel containing the headlight assembly on end to allow access to

the back of the headlight assembly.

11.Remove bolt and disengage the wire bail holding the headlight lamp in place

and move it out of the way.

12.Grasp the base of the lamp and lift it out.

13.Reverse the previous steps to replace the lamp and reassemble the panels.

High Beam Headlight Adjustment

The headlight beam can be adjusted to any position desired by turning the four

screws at the outer corners of the lamp housing.

1.Place the vehicle on a level surface with the headlight approximately 25’ (7.6

m) from a wall.

2.Measure the distance from the floor to the center of the headlight and make a

mark on the wall at the same height.

3.Start the engine and turn the headlight switch to high beam.

4.Observ e headlight aim. The most intense part of the headlight beam should

be aimed 2 ″ (5.1cm) belowthe mark placed on the wallin step 2. NOTE: Rider

weight must be included on the seat.

5.Adjust beam to desired position by turning screws on the housing.

117

MAINTENANCE

Headlight Lamp Replacement

Xplorer 400, Sportsman 500, Magnum 500

1.Remove Phillips screws from bottom of headlight pod at each front corner.

NOTE: To aid in accessing these screws, it may be helpful to turn handlebars

to left or right and use a short, stubby screwdriver. Removal of the front rack

and cover may also allow easier access.

2.Remove three Phillips screws at back of headlight pod.

3.Lift pod cover up. Disconnect s peedometer harnesses from speedometer. Un-

plug indicator light harness and remove pod cover.

4.Unplug headlamp from wiring harness.

5.Remove boot and locking collar from back of lamp housing.

6.Grasp base of lamp and lift it out.

7.Reverse previous steps to replace lamp and reassemble pod. Make sure tab

on lamp locks into place in housing.

High Beam Headlight Adjustment

The headlight beam can be adjusted to any position desired by turning the adjust-

ing knob located on the bottom right side of the headlight pod.

1.Place the vehicle on a level surface with the headlight approximately 25’ (7.6

m) from a wall.

2.Measure the distance from the floor to the center of the headlight and make a

mark on the wall at the same height.

3.Start the engine and turn the headlight switch to high beam.

4.Observ e headlight aim. The most intense part of the headlight beam should

be aimed 2 ″ (5.1cm) belowthe mark placed on the wallin step 2. NOTE: Rider

weight must be included on the seat.

5.Adjust beam to desired position by turning the adjustment knob.

Snap pins

into tabs

Position

knob in

slot and

secure in

locking

tabs

Slip O-Ring

over pin

Adjustment

Knob Stop

Route plug

over

handlebar

118

MAINTENANCE

Headlight Housing Replacement

1.Remove Phillips screws from bottom of headlight pod at each front corner.

NOTE: To aid in accessing these screws, it may be helpful to turn handlebars

to left or right and use a short, stubby screwdriver. Removal of the front rack

and cover may also allow easier access.

2.Remove three Phillips screws at back of

headlight pod.

3.Lift pod cover up. Disconnectspeedome-

ter harnesses from speedometer. Un-

plug indicator light harness and remove

pod cover.

4.Unplug headlamp from wiring harness.

5.RemoveO-Ring fromheadlightpivotpins.

6.Pull headlight housing up to release from

locking tabs.

7.Liftadjusting knobup toremove from lock-

ing tabs.

8.Carefully pull assemblyup and out ofpod.

9.Reverse steps to install new housing and

reassemble pod.

10.Adjust headlightaim by turning adjusting

knob.

O-Ring

51/8″

(13 cm)

Distance from headlamp parting

line to end of adjustment knob stop

is 5 1/8″ (13 cm).

119

MAINTENANCE

Taillight/Brakelight Lamp

Replacement

If the taillight/brakelight does not work the

lamp may need to be replaced.

1.From the rear of the taillight remove two

screws holding lens cover in place and

remove lens cover.

2.Remove lamp and replace itwith recom-

mended lamp.

3.Test the taillight/brakelight to see that it’s

working.

4.Reinst al lthe lens cover r emoved i n step 1.

Indicator Lamp Replacement - Style I

1.With a small, flat screwdriver gently pry

loose the indicator light cover.

2.Using a small flexible tube (such as an

oil delivery hose) grasp the burned out

lamp and remove it.

3.Replace the removed lamp with a Polar-

is PN 4030042 (Sylvania PN 12POL).

4.Replace the indicator light cover.

Indicator Lamp Replacement - Style II

1.Follow steps 1 - 3 of Headlight Housing

Replacement on previous page.

2.Unplug light from harness, depress lock-

ing tabs and remove from pod.

3.Install new light and reassemble pod.

Lens Cover

Bulb

Style I

Depress locking

tabs to remove.

Style II

120

MAINTENANCE

Cleaning Your ATV

Keeping your ATV clean will not only improve its appearance but itcan also extend

the life of various components. With a few precautions, your ATV can be cleaned

much like an automobile.

Washing

If a high pressure type car wash system is used, extreme care must be taken to

avoid water damage to the wheel bearings, transmission seals, body panels,

brakes and warning labels. Many expensive repair bills can result from using high

pressure detergent systems.

NOTE: If a high pressure car wash is used, grease all zerk fittings immediately af-

ter washing. Also run the vehicle to evaporate any water that might have entered

the engine or exhaust system.

The best and safest way to clean your ATV is with a garden hose and a pail of mild

soap and water. Use a professional type washing mitten, cleaning the upper body

first and the lower parts last. Rinse with water frequently and dry with a chamois

to prevent water spots. NOTE: If warning labels are damaged, contact your a Po-

laris dealer for free replacement.

Waxing

Your ATV can be waxed with any quality brand automotive paste wax. Avoid the

use of harsh cleaners since they can scratch the body finish.

CAUTION: Certain products, including insect repellants and chemicals, will

damage plastic surfaces. Care must be taken when using these products near

plastic surfaces.

Storage

IfyourATVistobeplacedinex-

tended or off season storage, the fol-

lowing steps should be taken to pre-

serve its condition.

1.Perform all necessary repairs and

thoroughly clean the ATV.

2.Turn the fuel valve to “off” and

drain the carburetor.

3.On 2-cycle engines, remove the

spark plug and pour approxi-

mately one ounce of injection oil

into the cylinder. Operate the

starter for a few seconds and re-

install the spark plug.

4.On 4-cycle engines, remove the spark plug and pour approximately one ounce

of Premium 4 oil into the cylinder. Operate the starter for a few seconds and

reinstall the spark plug.

5.Remove the battery. Store it in a cool, dry place out of the sun.

6.Lubricate suspension pivot points, lower steering post, all U-joints (if any) and

rear axle fittings (if any).

Drain tube

attached

here

Drain Screw

121

MAINTENANCE

Storage (Cont.)

7.Drain the recoil housing.

8.Block the ATV so all tires are sus-

pended off the ground.

9.Add Polaris Premium Storage Sta-

bilizer to the fuel tank (PN

2871326).

10.Coverthe ATVwitha canvascov-

er. Do not use plastic or coated

materials since they do not allow

ventilation of the vehicle.

Transporting

Whenever the ATV is to be transported the following measures should be taken.

1.Turnthefuelvalvetooff.

2.Be certain the fuel cap, oil cap, and seat are installed correctly.

3.Always tie the frame of the ATV to the transporting unit securely using suitable

straps or rope.

4.Always place the transmission in gear and lock the parking brake.

Carburetor Adjustments

Ifthe vehicle is tobe operated at variousaltitudes and temperatures,certainadjust-

ments can be made to improve its operation and driveability. Above 6000 feet

(1800m)theengine air/fuelmixturebecomes overlyrich. An enginelosesapproxi-

mately 3%ofitspowerforeach 1000 foot(304.8 m)increaseinelevation. Although

this power cannot be regained, changes to the carburetor and drive system can

be made to allow efficient operation. These changes include:

1.Carburetor re-jetting to compensate for altitude and/or temperature changes.

2.Transmission convertormodification toadjustforenginehorsepowerloss during

high altitude operation. Contact your dealer.

3.On 2 cycle models, air screw adjustments can be made to compensate for tem-

perature changes and/or changes in altitude.

4.On 4-cycle models, pilot screw adjustments can be made to compensate for

temperature changes and/or changes in altitude.

NOTE: Contact your dealer for altitude adjustments. They have the training and

special tools required to perform all necessary modifications for you.

Accessories

There are a wide range of Polaris Accessories available for ATVs. Contact your

Polaris dealer to find out about the accessories available for your machine.

Remove plug and drain the carburetor

400 Engines

122

TROUBLESHOOTING

Procedures

The following informationis providedto help you identify probable c auses forques-

tions you may have about the operation of your ATV. See your Polaris dealer with

any additional questions you may have.

ENGINE CRANKS BUT FAILS TO START

No Fuel Water in Fuel Spark Plug

Fuel Valve Off Drain System

No Spark to

Spark Plug

Contact Your

Dealer

Clogged Fuel

Valve or filter

ENGINE STOPS OR LOSES POWER

No Fuel

Contact Your

Dealer

Contact Your

Dealer

Overuse of

Choke

Spark Plug

Fouled

Engine

Overheated

Clean Engine

Exterior

Turn Fuel Valve

to “Res”

Water in Fuel

Air Filter

Clogged

Reverse Speed

Limiter

Malfunction

Electronic

Throttle Control

Malfunction

Fuel Vent Line

Kinked or

Plugged

Clean Radiator

screen and

Radiator Core

(liquid cooled

models)

123

WARRANTY

LIMITED WARRANTY

Polaris Industries Inc., 1225 Highway 169 North, Minneapolis, Minnesota

55441--5078, gives a SIX MONTH LIMITEDWARRANTYon a llcomponentsofthe

Polaris AllTerrain Vehicle(ATV) againstdefects inmaterialorworkmanship. Polar-

is also gives a one year limited warranty on the final drive chain for failure due to

defects. This warranty c overs the parts and labor charges for repair or replace-

ment of defective parts which are covered by this warranty. This warranty begins

on the date ofpurchase. This warrantyistransferrable toanotherconsumerduring

the warranty period through a Polaris dealer. There is a charge of $35.00 payable

to Polaris Industries Inc.

REGISTRATION

At the time of sale, the Warranty Registration Form must be completed by your

dealer and submitted to Polaris within ten days. Upon receipt of this registration,

Polaris will record the registration for warranty. THE PURCHASER MUST COM-

PLETE AN ATV SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN

ORDER TO HAVE VALID WARRANTY ON THE ATV. No verification of registra-

tion will be sent to the purchaseras the copy ofthe WarrantyRegistration Formwill

be the warranty entitlement. If you have not signed the original registration and re-

ceived the “customer copy”, please contact your dealer immediately. NO WAR-

RANTY COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REG-

ISTERED WITH POLARIS.

Initial dealer preparation and set --up of your ATV is very important in ensuring

trouble--free operation. Purchasinga machine in the crate orwithout properdealer

set--up will void your warranty coverage.

W ARRANTY COVERAGE AND EXCLUSIONS:

LIMITATIONS OF W ARRANTIES AND REMEDIES

The Polaris limited warranty excludes any failures that are not caused by a defect

inmaterialorworkmanship. This warranty does notcoveraccidentaldamage,nor-

mal wear and tear, abuse or improper handling. This warranty also does not cover

any ATV that has been altered structurally, modified, neglected, improperly main-

tained, used for racing, or used for purposes other than for which it was manufac-

tured, or for any damages which occur during trailer transit or as a result of unau-

thorized service or the use of unauthorized parts. In addition, this warranty does

not cover physical damage to paintor finish, stresscracks, tearing or puncturing of

upholstery material, corrosion, or defects in parts, components or the ATV due to

fire, explosions or any other cause beyond Polaris’ control.

124

WARRANTY

This warranty does not cover the use of unauthorized lubricants, chemicals, or

fuels that are not compatible with the ATV. The exclusive remedy forbreach ofthis

warranty shall be, at Polaris’ exclusive option, repair or replacement of any defec-

tive materials, or components or products. THE REMEDIES SET FORTH IN THIS

WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR

BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY

PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF

ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED

WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT

OR OTHERWISE. Some statesdo not permitthe exclusion orlimitation of inciden-

tal or consequential damages or implied warranties, so the above limitations or ex-

clusions 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 PARTICULAR

PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WAR-

RANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRAN-

TIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations 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 ATV requires warranty service, you must take it to a Polaris dealer autho-

rized to repair Polaris ATVs. When requesting warranty service you must present

yourcopy oftheWarranty Registrationform to thedealer. (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 Po-

laris 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 person at Polar-

is.

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 orfederallaw,all other warranty

terms will remain in effect.

Engine Oil

1. Always use Polaris engine oil.

2. Neversubstituteormixoilbrandsas serious engine damage and voiding of war-

ranty can result.

INDEX

125

Engine Cooling System 45-46..........

Air Cleaner 92-95....................

Air Filters 93-95......................

All Wheel Drive 43...................

Backing Up 71......................

Battery Installation 74................

Battery Maintenance 73..............

Battery Removal 7 4..................

Brake, Auxiliary 41 and 98.............

Brake, Front 97.....................

Brake, Parking 40...................

Brake, Rear 98......................

Brakes, Front 39....................

Brakes, Rear 39.....................

Break In Period 57...................

Break In Period -- 4 Cycle 56-57........

Breather Filter 95....................

Camber and Caster 96...............

Carburetor Adjustment (4 Cycle) 103...

Carburetor Adjustment (2 Cycle) 102...

Carburetor Adjustments 121...........

Cargo Weight Distribution 60..........

Carrying Loads 59...................

Chain Adjustment 112................

Choke Adjustment (4 Cycle) 102.......

Choke Adjustment Procedure 101......

Choke Lever 38.....................

Cleaning Your ATV 120...............

Control and Parts Functions 35-54......

Coolant Level 45....................

Coolant Level Inspection 46...........

Counter Balance Lubrication 108.......

Counter Balance Oil Changing

Procedure 108..................

Crossing Streams 69.................

Cylinder Head Torque 104.............

Daily Pre-ride Inspection 14 and 61.....

Demand 4 Drive 43..................

Disengaging Wheel Hubs 44..........

Draining Recoil Housing 54...........

Drive Chain Adjustment 11 1...........

Engine Choke Adjustment 103.........

Engine Choke Adjustment (400) 101....

Engine Electrical Switches 35.........

Engine Idle Rpm Adjustment 102-103...

Filter Change 49-50...................

Front Gearcase Lubrication 107........

Front Wheel Hub Tightening 89........

Fuel Filter 51........................

Fuel Safety 48......................

Fuel System 47.....................

Gearcase Oil Changing Procedure 107..

Handlebar Adjustment 88.............

Headlight Adjustment 113-117..........

Headlight Lamp Replacement 1 13-117...

Indicator Lamp Replacement 119.......

Indicator Lights 36...................

Light Switches 36....................

Load Capacity 59....................

Lubricant, 2cycle 52.................

Lubrication Recommendations 82-86....

Main Switch 35......................

Battery 73-74........................

Maintenance 76-121.................

Maintenance Record 87..............

Maintenance Schedule 79-81...........

Making Turns 63....................

Noise Control System 75.............

Oil Change 49-50....................

Oil Filter 51.........................

Oil Pump Adjustment 99-100..........

Oil Pump Bleeding 100...............

Oil System 47-49.....................

Operation Warnings 15-33.............

ParkingOnAnIncline 72.............

Power Pig Tail 78....................

Premium 4 Synthetic Lubricant 49......

PVT System 44.....................

Rear Spring Adjustment 90............

Recoil Starter 53....................

Riding 62-72.........................

Riding Gear 58......................

Riding On Slippery Surfaces 64........

Safety Warning and Operation

Decals 3-13.....................

Side Panel Removal 91...............

Sidehilling 66.......................

Spark Arrestor 76-77..................

Spark Plugs 104.....................

Starting A Cold Engine 55.............

Starting The Engine 55...............

Steering Inspection 96................

Storage 120-121....................

Taillight/Brakelight Lamp

Replacement 119...............

Throttle Cable Adjustment 101.........

Throttle Lever 38....................

Tire Inspection 110...................

Toe Alignment 96....................

Tool Kit 78..........................

Torque Specifications 89..............

Trail Obstacles 70...................

Transmission Gear Selector

Operation 42...................

Transmission Lubrication 105-106......

Transmission Oil Changing

Procedure 105-106..............

Transporting 121....................

Traveling Downhill 67................

Traveling Uphill 65...................

Troubleshooting 122.................

Turning Around On A Hill 68...........

Understanding W arnings 1-2...........

Vehicle Identification Numbers 34......

Warranty 124.......................

Warranty 123.......................

Wheel Installation 109................

Wheel Removal 109..................

Polaris 2000 Universal ATV

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