A card containing important ATV safety information should be attached to the
owner's manual on the next page. If you cannot locate this card, or if it has been
removed, please call 1-800-342-3764 for assistance.
WARNING
The engine exhaust from this
product contains chemicals known
to the State of California to cause
cancer, birth defects or other
reproductive harm.
1
Visit us at www.polarisindustries.com
2
POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc.
Copyright 2008 Polaris Sales Inc. All information contained within this publication is based on the latest product
information at the time of publication. Due to constant improvements in the design and quality of production
components, some minor discrepancies may result between the actual vehicle and the information presented in
this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability
can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures con-
tained within, whether whole or in part, is expressly prohibited.
Printed in U.S.A.
2009 Outlaw 450 MXR/525 S ATV Owner's Manual
P/N 9921801
3
Welcome
Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of
Polaris owners. We proudly produce an exciting line of utility and recreational products.
• Snowmobiles
• All-terrain vehicles (ATVs)
• RANGER utility vehicles
• Victory motorcycles
4
Welcome
We believe Polaris sets a standard of excellence for all utility and recreational vehicles man-
ufactured in the world today. Many years of experience have gone into the engineering,
design, and development of your Polaris vehicle, making it the finest machine we've ever
produced.
For safe and enjoyable operation of your vehicle, be sure to follow the instructions and rec-
ommendations in this owner's manual. Your manual contains instructions for minor mainte-
nance, but information about major repairs is outlined in the Polaris Service Manual and
should be performed only by a Factory Certified Master Service Dealer (MSD) Technician.
Your Polaris dealer knows your vehicle best and is interested in your total satisfaction. Be
sure to return to your dealership for all of your service needs during, and after, the warranty
period.
We also take great pride in our Pure Polaris products, available through our online store at
www.purepolaris.com. Have your accessories and clothing delivered right to your door!
5
Table of Contents
Introduction. . . . . . . . . . . . . . . . . . 6
Safety . . . . . . . . . . . . . . . . . . . . . 10
Features and Controls . . . . . . . . 38
Operation . . . . . . . . . . . . . . . . . . 58
Emission Control Systems . . . . . 85
Maintenance . . . . . . . . . . . . . . . . 87
Specifications . . . . . . . . . . . . . . 168
Polaris Products . . . . . . . . . . . . 172
Troubleshooting. . . . . . . . . . . . . 174
Warranty . . . . . . . . . . . . . . . . . . 186
Maintenance Log . . . . . . . . . . . 195
Index . . . . . . . . . . . . . . . . . . . . . 199
6
Introduction
Safety Words and Symbols
The following signal words and symbols appear throughout this manual and on your vehicle.
Your safety is involved when these words and symbols are used. Become familiar with their
meanings before reading the manual.
The safety alert symbol indicates a potential
personal injury hazard.
WARNING
A WARNING indicates a hazardous situation
which, if not avoided, may result in death or
serious injury.
CAUTION
A CAUTION indicates a hazardous situation
which, if not avoided, may result in minor or
moderate injury.
NOTICE
A NOTICE indicates a situation that may result in
property damage.
The Prohibition Safety Sign indicates
an action NOT to take in order to avoid
a hazard.
The Mandatory Action Sign indicates
an action that NEEDS to be taken to
avoid a hazard.
7
Introduction
Failure to follow the warnings and safety precautions contained in this manual can result in severe
injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles
differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly,
even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take
proper precautions.
• Read this owner’s manual. Understand all
safety warnings, precautions and operating
procedures before operating a Polaris ATV.
Keep this manual with the ATV.
• Never operate an ATV without proper
instruction. Take a training course. Purchasers
of a new Polaris ATV and their eligible family
members are entitled to take the ATV
RiderCourse
sm
. Contact ATV Enrollment
Express at (800) 887-2887 or visit
www.atvsafety.org for information on
enrollment in the ATV RiderCourse
sm
.
• This vehicle is an ADULT VEHICLE ONLY.
Operation is prohibited for anyone under 16
years of age.
• Never permit a guest to operate the ATV
unless the guest has read this manual and all
product labels and has completed a certified
safety training course.
WARNING
8
Introduction
Vehicle Identification Numbers
Record your vehicle's identification numbers and key number in the spaces provided.
Remove the spare key and store it in a safe place. An ignition key can be duplicated only by
ordering a Polaris key blank (using your key number) and mating it with one of your existing
keys. The ignition switch must be replaced if all keys are lost.
9
Introduction
Vehicle Identification Numbers
Vehicle Model Number: ________________________________________________________________________
Frame Vehicle Identification Number (1): __________________________________________________________
Engine Serial Number (2):______________________________________________________________________
Key Number (on the key): ______________________________________________________________________
2
1
10
Safety
Safety Training
ATV safety training is a top priority for
Polaris. When you purchased your new
ATV, your dealer instructed you on the
authorized ATV RiderCourse
sm
available to
you and your eligible family members. This
training is included in the purchase price of
your ATV. Polaris strongly encourages you
and your age eligible family members who
will be riding the ATV to take the ATV
RiderCourse
sm
.
You were also provided with printed materi-
als that explain safe operating procedures.
You should review this information on a
regular basis.
If you purchased a used Polaris ATV, you
can take the ATV RiderCourse
sm
by calling
ATV Enrollment Express at (800) 887-2887
or by visiting www.atvsafety.org.
Purchasers of a used Polaris ATV will be
charged for this training.
11
Safety
Safety Training
A Polaris ATV is an off-road vehicle.
Familiarize yourself with all laws and
regulations concerning the operation of this
vehicle in your area.
Follow the recommended maintenance
program outlined in your owner's manual.
This program is designed to ensure that all
critical components on your vehicle are
thoroughly inspected at specific intervals.
FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety
Commission at 1-800-638-2772, or visit www.cpsc.gov, visit www.atvsafety.org, or call
Polaris at 1-800-342-3764.
12
Safety
Equipment Modifications
We are concerned for the safety of our customers and for the general public. Therefore, we
strongly recommend that consumers do not install on a Polaris ATV any equipment that may
increase the speed or power of the vehicle, or make any other modifications to the vehicle for
these purposes. Any modifications to the original equipment of the vehicle create a substan-
tial safety hazard and increase the risk of bodily injury.
The warranty on your Polaris ATV is terminated if any equipment has been added to the
vehicle, or if any modifications have been made to the vehicle, that increase its speed or
power.
The addition of certain accessories, including (but not limited to) mowers, blades, tires,
sprayers, or large racks, may change the handling characteristics of the vehicle. Use only
Polaris-approved accessories, and familiarize yourself with their function and effect on the
vehicle.
13
Safety
Safe Riding Gear
Always wear clothing suited to the type of riding. ATV
riding requires special protective clothing for comfort and
to reduce the chance of injury.
Helmet
Wearing a helmet can prevent a severe head injury. When-
ever riding a Polaris vehicle, always wear a helmet that
meets or exceeds established safety standards.
Approved helmets in the USA and Canada bear a U.S.
Department of Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania bear the
ECE 22.05 label. The ECE mark consists of a circle sur-
rounding the letter E, followed by the distinguishing num-
ber of the country which has granted approval. The
approval number and serial number will also be displayed
on the label.
Helmet
Eye
Protection
Gloves
Boots
Long
Pants
Long
Sleeves
E
4
051039
0006.31
14
Safety
Safe Riding Gear
Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris
vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris
recommends wearing approved Personal Protective Equipment (PPE) bearing markings such
as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.
Gloves
Off-road style gloves with knuckle pads are the best for comfort and protection.
Boots
The best footwear is a pair of strong over-the-calf boots with low heels.
Clothing
Always wear long sleeves and long pants to protect arms and legs. Riding pants with knee-
pads and a jersey with shoulder pads provide the best protection.
15
Safety
Safety Warnings
Failure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which
may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s
manual. See the OPERATION section of the owner’s manual for proper operating procedures.
Operator Restrictions/Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for
anyone under 16 years of age. This category S (Sport) ATV is a high
performance vehicle intended for off road use only, for sport-type
recreation and for competitive use by operators with advanced skills
and substantial experience.
Even though a child may be within the recommended age group for
operating some ATVs, he/she may not have the skills, abilities, or
judgment needed to operate an ATV safely and could be susceptible to
accident or injury.
WARNING
16
Safety
Safety Warnings
Operating Without Instruction
Operating this ATV without proper instruction increases the risk of an
accident. The operator must understand how to operate the ATV
properly in different situations and on different types of terrain.
Beginning and inexperienced operators should complete the ATV
RiderCourse
sm
offered by Polaris through the SVIA. They should then
regularly practice the skills learned in the course and the operating
techniques described in the Owner's Manual.
For more information about the ATV RiderCourse
sm
contact ATV
Enrollment Express at (800) 887-2887 or visit www.atvsafety.org.
Never permit a guest to operate the ATV unless the guest has read
this manual and all product labels and has completed a certified
safety training course.
17
Safety
Safety Warnings
Handling Gasoline
Gasoline is highly flammable and explosive
under certain conditions.
• Always exercise extreme caution whenever
handling gasoline.
• Always refuel with the engine stopped, and
outdoors or in a well ventilated area.
• Do not smoke or allow open flames or sparks
in or near the area where refueling is per-
formed or where gasoline is stored.
• Do not overfill the tank. Do not fill the tank
neck.
• If gasoline spills on your skin or clothing,
immediately wash it off with soap and water
and change clothing.
Exposure to Exhaust
Engine exhaust fumes are poisonous and can
cause loss of consciousness or death in a short
time. Never start the engine or let it run in an
enclosed area.
The engine exhaust from this product contains
chemicals known to cause cancer, birth defects
or other reproductive harm. Operate this vehicle
only outdoors or in well-ventilated areas.
18
Safety
Safety Warnings
Failure to Inspect Before Operating
Failure to inspect and verify that the ATV is in
safe operating condition before operating
increases the risk of an accident. Always inspect
the ATV before each use to make sure it's in safe
operating condition. Always follow all inspection
and maintenance procedures and schedules
described in the owner's manual.
Protective Apparel
Operating this ATV without wearing an approved
helmet increases the risk of a serious head injury
in the event of an accident. Operating without
eye protection could result in an accident and
could increase the chance of a serious injury in
the event of an accident.
Always wear an
approved helmet that
fits properly. Always
wear eye protection
(goggles or face
shield), gloves, boots,
a long-sleeved shirt or
jacket and long pants.
19
Safety
Safety Warnings
Carrying a Passenger
Carrying a passenger greatly reduces the
operator's ability to balance and control the ATV,
which may result in an accident or overturn.
Never carry a passenger on this ATV.
Using Alcohol or Drugs
Operating the ATV after consuming alcohol or
drugs could adversely affect operator judgment,
reaction time, balance and perception. Never
consume alcohol or drugs before or while
operating an ATV.
20
Safety
Safety Warnings
Operating on Pavement
Operating an ATV on paved surfaces (including
sidewalks, paths, parking lots and driveways)
may adversely affect the handling of the ATV and
could result in loss of control and accident or
overturn. Avoid operating the ATV on pavement.
ATV tires are designed for off-road use. If it's
unavoidable, travel slowly and avoid sudden
turns or stops.
Operating on Public Roads
Operating this ATV on public streets, roads or
highways could result in a collision with another
vehicle. Never operate the ATV on any public
street, road or highway, including dirt and gravel
roads. In many states it's unlawful to operate
ATVs on public streets, roads and highways.
21
Safety
Safety Warnings
Operating at Excessive Speeds
Operating the ATV at excessive speeds
increases the operator's risk of losing control.
Always operate at a speed that's appropriate for
the terrain, the visibility and operating conditions,
and your experience.
Physical Control of the ATV
Removing a hand from the handlebars or feet
from the footpegs during operation can reduce
your ability to control the vehicle or cause loss of
balance and ejection from the ATV. If the
operator's foot is not firmly planted on the
footpeg, it could also contact the rear wheels.
Never remove your hands from the handlebars
while operating, and always keep both feet on
the footpegs.
22
Safety
Safety Warnings
Turning Improperly
Turning improperly could cause loss of traction,
loss of control, accident or overturn. Always
follow proper procedures for turning as described
in the owner's manual.
Never turn abruptly or at sharp angles. Never
turn at high speeds. Practice turning at slow
speeds before attempting to turn at faster
speeds.
Jumps and Stunts
Attempting wheelies, jumps and other stunts
increases the risk of an accident or overturn.
Never attempt wheelies, jumps, or other stunts.
Avoid exhibition driving.
23
Safety
Safety Warnings
Improper Hill Climbing
Improper hill climbing could cause loss of control
or overturn. Always follow proper procedures for
climbing hills as described in the owner's
manual. See page 72.
Operating on Steep Hills
Operating on excessively steep hills could cause
an overturn. Never operate on hills too steep for
the ATV or for your abilities. Never operate the
ATV on hills steeper than 25 degrees.
>25°
24
Safety
Safety Warnings
Descending Hills Improperly
Improperly descending a hill could cause loss of control or
overturn.
• Always follow proper procedures for traveling down hills as
described in the owner's manual. NOTE: A special tech-
nique is required when braking while traveling downhill. See
page 78.
• Always descend a hill with the transmission in forward gear.
Do not descend a hill with the transmission in neutral.
• Always check the terrain carefully before descending a hill.
• Shift your weight rearward.
• Never travel down a hill at high speed.
• Avoid traveling down a hill at an angle, which would cause
the vehicle to lean sharply to one side. Travel straight down
the hill when possible.
25
Safety
Safety Warnings
Crossing Hillsides
Driving on a sidehill is not recommended. Improper procedure
could cause loss of control or overturn. Avoid crossing the side
of any hill unless absolutely necessary.
If crossing a hillside is unavoidable, always follow proper
procedures as described in the owner's manual. See page 74.
Never attempt to turn the ATV around on any hill until you've
mastered the turning technique (on level ground) as described
in the owner's manual. See page 75.
26
Safety
Safety Warnings
Stalling While Climbing a Hill
Stalling, rolling backwards or improperly dismounting while climbing a
hill could cause an overturn.
Always maintain a steady speed when climbing a hill.
If all forward speed is lost
Keep body weight uphill. Apply the front brakes gradually (right
lever). When fully stopped, apply the foot brake as well, and then lock
the parking brake.
If the ATV begins rolling downhill:
Keep weight uphill. Never apply engine power. Never apply the rear
brake while rolling backwards. Apply the front brake slowly. When
fully stopped, apply the rear brake as well, and then lock the parking
brake. Dismount on uphill side, or to either side if ATV is pointed
straight uphill. Turn the ATV around and remount, following the
procedure described in the owner's manual. See page 75.
27
Safety
Safety Warnings
Operating on Slippery Terrain
Failure to use extra caution when operating on excessively
rough, slippery or loose terrain could cause loss of traction,
loss of control, accident or overturn.
Do not operate on excessively rough, slippery or loose
terrain until you've learned and practiced the skills necessary
to control the ATV on such terrain.
Always use extra caution on rough, slippery or loose terrain.
28
Safety
Safety Warnings
Operating in Unfamiliar Terrain
Failure to use extra caution when operating on
unfamiliar terrain could result in an accident or
overturn. Unfamiliar terrain may contain hidden
rocks, bumps, or holes that could cause loss of
control or overturn.
Travel slowly and use extra caution when
operating on unfamiliar terrain. Always be alert to
changing terrain conditions.
Operating Improperly in Reverse
Improperly operating in reverse could result in a
collision with an obstacle or person. Always
follow proper operating procedures as outlined in
this manual. See page 82.
Before shifting into reverse gear, always check
for obstacles or people behind the ATV. When it's
safe to proceed, back slowly.
Improper Tire Maintenance
Operating this ATV with improper tires or with
improper or uneven tire pressure could cause
loss of control or accident.
Always use the size and type of tires specified for
your ATV. Always maintain proper tire pressure
as described in the owner's manual and on
safety labels.
29
Safety
Safety Warnings
Improper Vehicle Modifications
Improper installation of accessories or
modification of the ATV may cause changes in
handling, which could cause loss of control or an
accident.
Never modify the ATV through improper
installation or use of accessories. All parts and
accessories added to the vehicle must be
genuine Polaris Industries Inc. or equivalent
components designed for use on this ATV and
should be installed and used according to
approved instructions. See your authorized
Polaris ATV dealer for more information.
Operating Over Obstacles
Improperly operating over obstacles could cause
loss of control or overturn.
Before operating in a new area, check for
obstacles. Avoid operating over large obstacles
such as rocks and fallen trees. If unavoidable,
use extreme caution and always follow proper
operating procedures as outlined in this manual.
See page 84.
Skidding or Sliding
Skidding or sliding can cause loss of control or
overturn (if tires regain traction unexpectedly).
On slippery surfaces such as ice, travel slowly
and use extra caution to reduce the chance of
skidding or sliding.
30
Safety
Safety Warnings
Operating Through Deep Water
Operating the ATV through deep or fast-flowing water could cause the tires to float, causing loss of
control or overturn. Avoid operating through deep or fast-flowing water. If it's unavoidable to enter water
that exceeds the height of the footpegs:
• Travel slowly.
• Balance your weight carefully.
• Avoid sudden movements.
• Maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make
sudden throttle changes.
• Wet brakes may have reduced stopping ability. After leaving water, test the brakes. Apply them
lightly several times while driving. The friction will help dry out the pads.
31
Safety
Safety Warnings
Poor Visibility
Operating the ATV in darkness or inclement weather could result in a collision or accident, especially if
operating on a road or street. This ATV is not equipped with highway-approved lights. Operate this
vehicle off-road only. Use caution and drive at reduced speeds in conditions of reduced visibility such
as fog, rain and darkness. Clean headlights frequently and replace burned out headlamps promptly.
Improper Cargo Loading
Overloading the ATV or carrying/towing cargo may cause
changes in handling, which could cause loss of control or
an accident. Never haul cargo or tow a load with this ATV.
Never tow or pull an object behind the ATV. A wagon, sled
or other towed object does not have brakes or steering.
The object may overturn or collide with other objects.
Never exceed the stated load capacity for this ATV.
32
Safety
Safety Warnings
Operating on Frozen Bodies of Water
Operating on frozen bodies of water may result in
serious injury or death if the ATV and/or the
operator fall through the ice. Never operate the
ATV on a frozen body of water.
Operating a Damaged ATV
Operating a damaged ATV can result in an
accident. After any overturn or accident, have a
qualified service dealer inspect the entire
machine for possible damage, including (but not
limited to) brakes, throttle and steering systems.
Physical Skills
Safe operation of this rider-active vehicle
requires good judgement and physical skills.
Persons with cognitive or physical disabilities
who operate this vehicle have an increased risk
of overturn and loss of control.
33
Safety
Safety Warnings
Hot Exhaust Systems
Exhaust system components are very hot during
and after use of the vehicle. Hot components can
cause burns and fire. Do not touch hot exhaust
system components. Always keep combustible
materials away from the exhaust system. Use
caution when traveling through tall grass,
especially dry grass.
Unauthorized Use of the ATV
Leaving the keys in the ignition can lead to
unauthorized use of the vehicle, which could
result in an accident or overturn. Always remove
the ignition key when the vehicle is not in use.
34
Safety
Safety Labels and Locations
Warning labels have been placed on the
vehicle for your protection. Read and
follow the instructions on each label
carefully. If any of the labels shown in
this manual differ from the labels on
your vehicle, always read and follow
the instructions of the labels on the
vehicle.
If an informational or graphic label
becomes illegible or comes off, contact
your Polaris dealer to purchase a
replacement.
Replacement safety labels are provided
by Polaris at no charge. The part num-
ber is printed on the label.
Age 16
Warning
General Warning
Discretionary/Sport ATV
Warning
35
Safety
Safety Labels and Locations
General Warning
WARNING
Improper ATV use can result in SEVERE
INJURY OR DEATH.
Always use an approved helmet and protective
gear. Never use on public roads. Never carry
passengers. Never use with drugs or alcohol.
NEVER operate:
• without proper training or instruction
• at speeds too fast for your skills or the condi-
tions
• on public roads - a collision can occur with
another vehicle
• with a passenger - passengers affect balance
and steering and increase risk of losing control
ALWAYS:
• use proper riding techniques to avoid vehicle
overturns on hills and rough terrain and in
turns
• avoid paved surfaces - pavement may seri-
ously affect handling and control.
LOCATE AND READ OWNER'S MANUAL.
FOLLOW ALL INSTRUCTIONS AND
WARNINGS.
7175376
36
Safety
Safety Labels and Locations
Age 16 Warning
WARNING
Operating this ATV if you are under the age of 16
increases your chance of severe injury or death.
NEVER operate this ATV if you are under age
16.
7175374
Discretionary/Sport ATV Warning
WARNING
• Never operate this ATV on HILLS steeper than
25 degrees 25
°. To prevent overturn on
hilly terrain, use throttle and brakes gradually
and shift weight uphill.
• REVERSE operation can be dangerous even
at low speeds. Steering becomes difficult. To
prevent loss of control, avoid sudden braking
or sharp turns.
This ATV may exceed the performance of other
ATVs you may have ridden in the past. This
category S (Sport) ATV is a high performance
vehicle for off-road use only, in sport type
recreation and competitive use by operators with
advanced skills and substantial experience.
7175637
37
Safety
Safety Labels and Locations
No Passenger Warning
WARNING
NEVER ride as a passenger.
Passengers can cause a loss of control, resulting
in SEVERE INJURY or DEATH.
7175378
Tire Pressure/Load Warning
WARNING
Improper tire pressure or overloading can cause
loss of control.
Loss of control can result in severe injury or
death.
• Cold tire pressure:
Front: 4.0 psi (27.6 kPa)
Rear: 4.0 psi (27.6 kPa)
• Maximum Weight Capacity 215 lbs. (98 kg)
7175445
Tire Pressure
Warning
No
Passenger
Warning
38
Features and Controls
Start
Button
Engine
Stop Switch
Main Key Switch
39
Features and Controls
Main Key Switch
The main key switch must be in the RUN position to start the engine. See page 66 for starting
procedures.
Start Button
Press the start button to engage the starter. Always release the start button promptly when the
engine starts. If the starter fails to engage, replace the blown fuse or see your Polaris dealer.
Engine Stop Switch
Move the stop switch either left or right to the OFF
position to stop the engine quickly. The engine will
not start or run when the switch is off.
Both the main switch and the engine stop switch will
shut off all electrical power to the vehicle, including
lights.
OFF OFFRUN
40
Features and Controls
Lights
Indicator Lights
An illuminated light in the indicator
window will alert you to the follow-
ing conditions.
• Hot engine
• Reverse gear is selected
• Neutral gear is selected
If indicator lights fail to operate,
check connections. See your Polaris
dealer for inspection of the capacitor
and voltage regulator.
Reverse
Neutral
Hot Engine
41
Features and Controls
Lights
Headlights
Use the headlight switch to turn the lights
on and off and to change the lights from
high beam to low beam. The key must be in
the ON position and the engine stop switch
must be in the RUN position to operate the
headlights.
Headlight Switch
42
Features and Controls
Clutch Lever
The hydraulic clutch lever is located on the left handlebar.
Squeeze the clutch lever toward the handlebar to disengage
the clutch. Disengage the clutch before shifting gears.
The clutch is self-adjusting, but lever position can be
changed to fit the operator’s hand. Turn the adjusting knob
counterclockwise to move the lever closer to the handle-
bar. Turn the adjusting knob clockwise to move the lever
away from the handlebar.
The adjustment range is limited. Never apply excessive force to the knob. Always turn the
knob manually.
Always check the lever for smooth operation before riding. If the lever does not operate
smoothly, check the fluid level at the master cylinder. See page 43.
If the lever begins to feel unresponsive, bleed the clutch system as outlined on page 138.
Adjusting Knob
43
Features and Controls
Clutch Fluid
The clutch fluid master cylinder is located on the
left handlebar. Check the fluid level in the reservoir
before each ride. The level should be 4mm below
the upper edge of the reservoir. Do not overfill.
Polaris recommends the use of KTM Hydraulic
Clutch Oil. Do not use brake fluid. Do not mix
clutch fluid with any other hydraulic fluids. See
page 172 for the part numbers of Polaris products.
1. Position the vehicle on a level surface.
2. Turn the handlebar until the master cylinder is
in a horizontal position.
3. Remove the two cover screws, the cover and the
rubber boot.
4. Add the recommended fluid as needed.
5. Reinstall the cover, boot and screws securely.
Screws
Cover
Boot
44
Features and Controls
Throttle Lever
Operating an ATV with sticking or improperly operating throttle controls could cause an accident. Never
start or operate an ATV that has a sticking or improperly operating throttle. Always contact your dealer
for service before operating the vehicle.
Failure to check or maintain proper operation of the throttle system can result in an accident if the
throttle lever sticks during operation. Always check the lever for free movement and return before
starting the engine. Also check occasionally during operation.
Modifications to the electronic throttle control could result in failure to perform as designed, which could
result in an accident. Do not attempt to modify the throttle control system or replace it with any after
market throttle mechanisms. Always ensure that the throttle cable is properly installed to the throttle
control.
WARNING
45
Features and Controls
Throttle Lever
The throttle lever is located on the right handlebar. Squeeze the lever toward the handlebar to
increase engine speed and vehicle movement.
Fuel is injected into the intake passage each time throttle is applied. Do not squeeze the throt-
tle lever while starting the engine. Do not squeeze the throttle lever when the engine is
stopped.
Engine speed returns to idle when the lever is released.
See page 141 for throttle adjustment procedures.
This ATV is equipped with Polaris Electronic Throttle
Control (ETC), which is designed to reduce the risk of a
frozen or stuck throttle. If the throttle cable should stick
in an open position when the operator releases the throt-
tle lever, the engine will stop, and power to the rear
wheels will cease.
Throttle Lever
46
Features and Controls
Foot Brake
The foot brake operates the rear brakes. The
brake pedal is located in front of the right-hand
footpeg. If the rear wheels slide while using
the foot brake, reduce brake pedal pressure to
brake the wheels without skidding.
Check the brake fluid level frequently for the
foot brake system. The reservoir is located
under the seat. Maintain the fluid level
between the minimum and maximum marks.
WARNING! Aggressively applying the foot brake when backing down a hill may cause rear tipover,
which could result in serious injury or death. Never back down a hill. Use caution when applying the
foot brake. Do not aggressively apply the foot brake when going forward. The rear wheels may skid
and slide sideways, causing loss of control.
Footpeg
Foot Brake
(Rear Brake)
47
Features and Controls
Hand Brake
The hand brake operates the front brakes. The hand
brake is located on the right handlebar.
These brakes
are hydraulically activated disc type brakes.
Squeeze
the brake lever toward the handlebar to engage the
front brakes.
Always test brake lever travel and master cylinder
fluid level before riding. When squeezed, the lever
should feel firm. Any sponginess would indicate a
possible fluid leak or low master cylinder fluid level,
which must be corrected before riding. Contact your
dealer for proper diagnosis and repairs.
WARNING! Operating the ATV with a spongy brake lever can result in loss of braking, which could
cause an accident. Never operate the ATV with a spongy-feeling brake lever. Always contact your
dealer for service before operating the vehicle.
Hand Brake
(Front Brake)
48
Features and Controls
Master Cylinder/Brake Fluid
An over-full master cylinder may cause brake drag or brake lock-up, which could result in an accident.
Maintain brake fluid at the recommended level. Do not overfill.
Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs
moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can
lead to early brake fade and the possibility of brake failure, which could result in an accident. After
opening a bottle of brake fluid, always discard any unused portion.
WARNING
49
Features and Controls
Master Cylinder/Brake Fluid
Check the brake fluid in the master cylinder before each ride. If the fluid level is low add
DOT 4 brake fluid only. Do not overfill. See page 172 for the part numbers of Polaris prod-
ucts.
Hand Brake Fluid Level
1. Position the ATV on a level surface. Position the
handlebars so the master cylinder is level.
2. View the fluid level through the indicator window
on the side of the master cylinder.
3. Maintain the fluid level at or slightly above the
mark near the center of the sight glass. Do not
overfill.
Foot Brake Fluid Level
1. Position the ATV on a level surface.
2. Remove the seat and view the fluid level in the reservoir. Maintain the fluid level
between the maximum and minimum marks.
Fluid Level Mark
50
Features and Controls
Parking Brake
1. Place the transmission in first gear.
2. Squeeze and release the brake lever two or
three times, then squeeze and hold.
3. Push the parking brake lock down to engage
the lock. Release the brake lever.
4. To release the parking brake lock, squeeze
and release the brake lever. The lock will
automatically disengage.
WARNING! Operating the ATV while the parking
brake is engaged could result in an accident. Always
check to be sure the parking brake is disengaged
before operating.
51
Features and Controls
Parking Brake
The parking brake may relax if left on for a long period of time. Always block the wheels to
prevent rolling. Always block the wheels on the downhill side of the ATV if leaving it parked
on a hill. Another option is to park the ATV in a sidehill position. Never depend on the park-
ing brake alone if the ATV is parked on a hill. Always block the wheels to prevent rolling.
52
Features and Controls
Manual Shift
Shift Pedal
The gear shift pedal is located in front of the left-hand footpeg. One
full stroke of the pedal shifts the transmission to the next gear in the
shifting sequence. The pedal automatically returns to a horizontal
position when released.
To upshift to a higher gear, place the toe of your boot under the gear
shift pedal and raise the pedal one full stroke. See page 53.
To downshift, place your foot on the gear shift pedal and depress the
pedal one full stroke. See page 53.
To shift into reverse, see page 54.
Upshift
Downshift
53
Features and Controls
Manual Shift
Shifting Gears
Always allow a cold engine to warm up
before shifting gears.
1. When starting from a stopped position,
place the transmission in neutral.
2. Squeeze and hold the brake lever. Do
not apply throttle.
3. Squeeze the clutch lever to disengage
the clutch.
4. Depress the gear shift pedal one full
stroke to shift into first gear.
5. Release the brake lever.
6. Gradually squeeze the throttle lever
while slowly releasing the clutch lever.
7. As engine speed (RPM) increases in
first gear, simultaneously release the
throttle, disengage the clutch and shift
to second gear by raising the gear shift
pedal one full stroke. Repeat this proce-
dure to progressively upshift to addi-
tional gears. Use the same procedure to
downshift.
WARNING! Shifting without releasing the throttle
and disengaging the clutch could cause loss of
control or vehicle overturn. Always release the
throttle and fully squeeze the clutch lever while
shifting gears.
54
Features and Controls
Manual Shift
Reverse Lock-Out Switch
The reverse lock-out switch prevents the
operator from shifting into reverse uninten-
tionally. The switch must be manually
unlocked before shifting into reverse gear.
The lock will automatically re-engage when
the transmission is shifted out of reverse gear.
1. Place the transmission in first gear. See
page 52.
2. Push the lock-out lever forward toward
the handlebar to unlock the transmission.
3. Shift down into reverse gear.
Lock-Out Lever
55
Features and Controls
Manual Shift
Deceleration
To slow or stop the vehicle, release the throttle lever and apply the brakes smoothly and
evenly. As the vehicle slows and engine speed decreases, disengage the clutch and shift to a
lower gear. Be sure engine speed has sufficiently decreased before downshifting.
WARNING! Improper use of the brakes or shifting when the engine speed is too high can cause the
tires to lose traction or stop rotating, which could result in loss of control.
NOTICE: Shifting when engine speed is too high can also cause engine and drive train damage.
56
Features and Controls
Choke
The choke assists in starting a cold engine. The choke
knob is located on the left side of the carburetor. Refer
to the engine starting procedure on page 66 for correct
choke and throttle settings during starting.
Fuel Tank
The fuel tank filler cap is located directly below the
handlebar. Polaris recommends the use of 91 octane or
higher fuel. Do not use E-85 fuel.
Fuel Filter
The fuel tank has an internal fuel filter. Do not attempt
to clean the fuel filter. See your Polaris dealer for service if you suspect the fuel filter is
plugged.
Choke Knob
57
Features and Controls
Fuel Valve
The fuel valve is located on the right side of the
ATV. It has three positions:
OFF: For vehicle storage and when transporting.
Turn the fuel valve off whenever the vehicle is
stored or parked.
ON: For normal operation.
RES: For reserve supply if main supply is
exhausted. There's about a 5 to 8 mile (8 to 13 km)
range on reserve gas. Always refill the gas tank as
soon as possible after using the main supply.
Always return the valve to the ON position after
refueling.
Fuel Valve
58
Operation
Failure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which
may result in serious injury or death. Read and understand all safety warnings outlined in the safety
section of this owner’s manual.
Break-In Period
The break-in period for your new Polaris ATV is the first three hours of operation, or the
time it takes to use 5-6 gallons (20 liters) of fuel. No single action on your part is as impor-
tant as following the procedures for a proper break-in. Careful treatment of a new engine and
transmission will result in more efficient performance and longer life for both.
Do not allow engine speed to exceed 7000 RPM during the break-in period. Follow the
break-in period with an additional 12 hours of cautious operation, with engine speed below
75% of capacity.
NOTICE: Failure to perform the recommended break-in maintenance can result in serious engine
damage.
WARNING
59
Operation
Break-In Period
Perform the following break-in and maintenance procedures carefully.
1. Fill the fuel tank with gasoline. Always
exercise extreme caution whenever han-
dling gasoline.
2. Check the oil level. Add the recom-
mended oil as needed to maintain the oil
level in the proper range. See page 99.
3. Allow the engine sufficient time to
warm up before operating.
4. Drive slowly at first. Select an open
area that allows room to familiarize
yourself with vehicle operation and
handling.
5. Excessive heat build-up during the first
three hours of operation will damage
close-fitted engine parts. Do not allow
engine speed to exceed 7000 RPM dur-
ing the first three hours of use.
6. Vary throttle positions. Do not operate
at sustained idle.
7. Perform regular checks on fluid levels,
controls and areas outlined on the daily
pre-ride inspection checklist. See page
60.
8. At the end of the break-in period (3
hours), change the engine oil and the
long and short oil filters. See page 100.
Clean the oil screen and drain plug
magnet.
60
Operation
Pre-Ride Inspection
Failure to inspect and verify that the ATV is in safe operating condition before operating
increases the risk of an accident. Always inspect the ATV before each use to make sure it's in
safe operating condition.
Pre-Ride Checklist Page
Brake systems / lever travel Ensure proper operation 46-51
142-143
Brake fluid Ensure proper level 48
Clutch lever Check for proper operation and adjustment 42
Clutch fluid Ensure proper level 43
Suspension, front and rear Inspect, lubricate if necessary 94
Steering Check for free operation/loose components --
Frame nuts, bolts, fasteners Inspect, ensure tightness --
Fuel and oil Ensure proper levels 56, 99
61
Operation
Pre-Ride Inspection
Pre-Ride Checklist Page
Coolant (if applicable) Ensure proper level 109
Coolant hoses (if applicable) Inspect for leaks --
Throttle Ensure smooth operation 44
Indicator lights / switches Ensure operation 40, 41
Engine stop switch Ensure proper operation 39
Air filter Inspect, clean, replace as needed 112
Air box sediment tubes Drain deposits when visible --
Headlamp Verify operation, apply Polaris dielectric grease to
the socket when the lamp is replaced
118
Brake light / tail lamp Verify operation --
Riding gear Wear helmet, goggles, protective clothing 13
A-arm ball joints Check freeplay. If the tire moves excessively, do not
operate. See your Polaris dealer.
--
62
Operation
Safe Operation Practices
1. Complete the recommended safety
training before operating this vehicle.
See page 10.
2. Do not allow anyone under 16 years of
age to operate this vehicle. Do not allow
anyone with cognitive or physical dis-
abilities to operate this vehicle.
3. Never carry a passenger on this ATV.
4. Engine exhaust fumes are poisonous.
Never start the engine or let it run in an
enclosed area.
5. Operate this vehicle off-road only.
Never operate the vehicle on pavement
or on any public street, road or highway,
including dirt and gravel roads.
6. Use caution and drive at reduced speeds
in conditions of reduced visibility such
as fog, rain and darkness. Clean head-
lights frequently and replace burned out
headlamps promptly.
7. Never exceed the maximum weight
capacity of the vehicle. When determin-
ing the weight you are adding to the
vehicle, include the weight of the opera-
tor, accessories, loads on the racks (if
equipped) and the load on the trailer
tongue (if equipped). The combined
weight of these items must not exceed
the maximum weight capacity.
63
Operation
Safe Operation Practices
8. Drive in a manner appropriate for your
skills and operating conditions. Never
operate at excessive speeds. Never
attempt wheelies, jumps, or other stunts.
Never remove your hands from the han-
dlebars while operating, and always
keep both feet on the footpegs.
9. Never consume alcohol or drugs before
or while operating an ATV.
10. Always use the size and type of tires
specified for your vehicle. Always
maintain proper tire pressure.
11. Never operate a damaged ATV. After
any overturn or accident, have a quali-
fied service dealer inspect the entire
machine for possible damage.
12. Never operate the ATV on a frozen
body of water.
13. Do not touch hot exhaust system com-
ponents. Always keep combustible
materials away from the exhaust sys-
tem.
14. Always remove the ignition key when
the vehicle is not in use to prevent unau-
thorized use.
64
Operation
Know Your Riding Area/Tread Lightly
Familiarize yourself with all laws and regulations concerning the operation of this off-road
vehicle in your area. Respect the environment in which you ride. Find out where the desig-
nated riding areas are by contacting your Polaris dealer, a local riding club or local officials.
Help keep our trails open for recreational vehicle use. As an off-road enthusiast, you repre-
sent the sport and can set a good example (or a poor example) for others to follow. Tread
lightly. Operate with respect for the terrain, avoid littering, and always stay on the designated
trails.
65
Operation
Trail Etiquette
Always practice good etiquette when riding. Allow a safe distance between your vehicle and
other vehicles operating in the same area. Communicate to oncoming operators by signaling
the number of vehicles in your group. When stopping, move your vehicle to the edge of the
trail as far as possible to allow others to pass safely.
66
Operation
Starting the Engine
The engine can be started when the transmission is in neutral, or while in gear if the clutch is
disengaged. If starting a warm engine, do not use the choke.
Fuel is injected into the intake passage each time the throttle lever is depressed. Do not
depress the throttle lever while starting the engine. Do not depress the throttle lever when the
engine is stopped.
NOTICE: Operating the ATV immediately after starting could cause engine damage. Allow the engine
to warm up for several minutes before operating.
1. Shift the transmission to neutral.
2. Lock the parking brake. Turn the fuel valve on.
3. Sit on the vehicle. Disengage the clutch.
4. If the engine is cold, pull the choke knob out until it
stops. Do not use the choke if starting a warm
engine.
Choke Knob
67
Operation
Starting the Engine
5. Move the engine stop switch to the RUN position. Turn the ignition key to ON.
6. If starting the engine while in gear, apply the hand brake and squeeze the clutch lever
fully to disengage the clutch. If starting the engine while in neutral, the neutral indicator
light should be on. If it isn't, disengage the clutch and shift the foot pedal to find neutral.
See page 52.
7. Do not apply throttle. Press the start button to start the engine. Activate the starter for a
maximum of five seconds. Release the start button immediately when the engine starts.
NOTICE: Excessive engagement may result in starter damage.
8. If the engine does not start, wait five seconds after releasing the start button, then acti-
vate the starter for another five seconds. Repeat until the engine starts. If the engine does
not start, review the engine troubleshooting information beginning on page 174. If all
conditions are favorable and the engine still does not start, see your Polaris dealer for
service.
9. Push the choke knob completely in. Vary engine speed slightly with the throttle to aid in
warm-up.
68
Operation
Driving Procedures
1. Wear a helmet and eye protection.
2. Sit upright with both feet on the footpegs and
both hands on the handlebars.
3. Start the engine and allow it to warm up.
4. Shift the transmission into gear. See page 52.
5. Check your surroundings and determine your
path of travel.
6. Release the parking brake.
7. Slowly depress the throttle with your right
thumb while slowly releasing the clutch lever to
begin driving.
8. Drive slowly. Practice maneuvering and using
the throttle, clutch and brakes on level surfaces.
69
Operation
Making Turns
Your ATV is equipped with a solid rear axle, which drives both
rear wheels equally at all times. The wheel on the outside of the
turn travels a greater distance than the inside wheel when turn-
ing, and the inside tire slips 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 footpeg. 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 turn-
ing in reverse.
Practice making turns at slow speeds before attempting to turn
at faster speeds.
WARNING! Turning improperly can result in vehicle overturn. Never turn abruptly or at sharp angles.
Never turn at high speeds.
70
Operation
Driving on Slippery Surfaces
Whenever riding on slippery surfaces such as
wet trails or loose gravel, or during freezing
weather, follow these precautions:
1. Do not operate on excessively rough, slip-
pery or loose terrain.
2. Slow down when entering slippery areas.
3. Maintain a high level of alertness, reading
the trail and avoiding quick, sharp turns,
which can cause skids.
71
Operation
Driving on Slippery Surfaces
4. Never apply the brakes during a skid. Correct a skid by turning the handlebars in the
direction of the skid and shifting your body weight forward.
Sideways
skid
Turn in
direction of
skid
72
Operation
Driving Uphill
Braking and handling are greatly affected when
operating in hilly terrain. Improper procedure
could cause loss of control or overturn. When-
ever traveling uphill, follow these precautions:
1. Drive straight uphill.
2. Avoid steep hills (25
° maximum).
3. Always check the terrain carefully before
ascending any hill.
4. Never climb hills with excessively slippery
or loose surfaces.
25° Maximum
73
Operation
Driving Uphill
5. Keep both feet on the footpegs.
6. Shift body weight uphill.
7. Proceed at a steady rate of speed and throttle opening. Opening the throttle suddenly
could cause the ATV to flip over backwards.
8. Never back down a hill.
WARNING! Aggressively applying the foot brake when backing down a hill may cause rear tipover.
9. 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.
10. Remain alert and be prepared to take emergency action. This may include quick dis-
mounting of the vehicle.
74
Operation
Driving on a Sidehill (Sidehilling)
Driving on a sidehill is not recommended. Improper procedure could cause loss of control or
overturn. Avoid crossing the side of any hill unless absolutely necessary.
If crossing a sidehill is unavoidable, follow these precautions:
1. Slow down.
2. Lean into the hill, transferring your
upper body weight uphill while keep-
ing your feet on the footpegs.
3. If the vehicle begins to slide or tip,
quickly turn the front wheel down-
hill, if possible, or dismount on the
uphill side immediately!
75
Operation
Turning Around on a Hill
If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn
around:
1. Keep your body weight uphill.
2. Pull in the clutch lever and apply the front and rear brakes.
3. When completely stopped, shut off the engine. Leaving the transmission in gear, release
the clutch lever and lock the parking brake.
4. Dismount on the uphill side of the vehicle, or on the left side if the vehicle is pointing
straight uphill.
5. Staying uphill of the ATV, turn the handlebars full left.
6. Reach across the handlebar and apply the front brakes to unlock the parking brake.
76
Operation
Turning Around on a Hill
7. With the front brakes applied, pull in the
clutch lever. Use the brakes to slowly allow
the vehicle to roll around to your right until
it's pointing across the hill or slightly down-
ward.
8. With the front brakes still applied, release
the clutch lever and lock the parking brake.
Remount from the uphill side, keeping body
weight uphill.
8 ft. (2.4 m)
77
Operation
Turning Around on a Hill
9. Pull in the clutch lever, shift into neutral and restart the engine.
10. Release the parking brake and slowly release the clutch lever, allowing the ATV to pro-
ceed slowly. Stay in first gear, using the brakes for additional speed control if necessary,
until more level ground is reached.
11. Follow proper procedures for driving downhill. See page 78.
78
Operation
Driving Downhill
When driving downhill, follow these precautions:
1. Avoid steep hills (25
° maximum).
2. Shift body weight uphill. Transfer your
weight to the rear of the vehicle.
3. Drive straight downhill.
4. Slow down. Excessive speed when traveling
downhill can cause loss of control.
5. Shift to the lowest gear possible while main-
taining a safe speed.
6. Do not apply the brakes abruptly when driv-
ing downhill. Apply the foot brake slightly to
aid in slowing.
79
Operation
Parking on a Hill or Incline
Avoid parking on an incline if possible. If
it's unavoidable, follow these precau-
tions:
1. Stop the engine.
2. Place the transmission in first gear.
3. Lock the parking brake.
4. Always block the rear wheels on the
downhill side. See illustration.
5. Turn the fuel valve off.
80
Operation
Driving Through Water
Polaris does not recommend operating
in water deeper than the height of the
footpegs. Follow these precautions
when operating through water:
1. Determine water depth and current
before entering water.
2. Choose a crossing where the water
level is lowest and where both
banks have gradual inclines.
3. Avoid operating through deep or
fast-flowing water.
Maximum Depth
81
Operation
Driving Through Water
NOTICE: Serious engine damage can result if the vehicle is not thoroughly inspected after operating
in water deeper than the footpeg level. As soon as possible, perform the inspections and
maintenance services outlined in the periodic maintenance chart beginning on page 87.
Engine oil and all grease fittings need special attention.
If the vehicle tips or overturns in water, or if the engine stops during or after operating in
water, restarting can result in serious engine damage. Transport the vehicle to your dealer
for service before restarting the engine. If this is not possible, follow the vehicle immersion
inspection and drying procedures outlined on page 126, then see your dealer for service at
the first opportunity.
4. After leaving water, test the brakes. Apply them lightly several times while driving. The
friction will help dry out the pads.
If it’s unavoidable to enter water deeper than the footpeg level:
• Proceed slowly. Avoid rocks and obstacles.
• Balance your weight carefully. Avoid sudden movements.
• Maintain a steady rate of speed. Do not make sudden turns or stops. Do not make sudden
throttle changes.
82
Operation
Driving in Reverse
Follow these precautions when operat-
ing in reverse:
1. Always check for obstacles or peo-
ple behind the vehicle.
2. Always avoid backing downhill.
3. Back slowly.
4. Apply the brakes lightly for stop-
ping.
5. Avoid turning at sharp angles.
6. Never open the throttle suddenly
while backing.
83
Operation
Driving in Reverse
7. Do not operate at full throttle. Use just enough throttle to maintain a desired speed.
8. Always look left, right and behind the ATV before backing.
NOTICE: Excessive throttle operation while in the speed limit mode may cause fuel to build in the
exhaust, resulting in engine popping and/or engine damage.
84
Operation
Driving Over Obstacles
Follow these precautions when operating
over obstacles:
1. Always check for obstacles before oper-
ating in a new area.
2. Look ahead and learn to read the terrain.
Be constantly alert for hazards such as
logs, rocks and low hanging branches.
3. Travel slowly and use extra caution
when operating on unfamiliar terrain.
Not all obstacles are immediately visible.
4. Never attempt to operate over large
obstacles, such as rocks or fallen trees.
85
Emission Control Systems
Noise Emission Control System
Do not modify the engine, intake or exhaust components, as doing so may affect compliance
with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level require-
ments.
Operation on Public Lands in the U.S.A.
Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance
with the USDA Forest Service Standard 5100-1C. Federal law requires that this spark arres-
tor be installed and functional when the vehicle is operated on public lands.
Operation of off-road vehicles on public lands in the U.S.A. is regulated by 43 CFR
8343.1(c). Violations are subject to monetary penalties. Federal regulations can be viewed
online at www.gpoaccess.gov/ecfr/.
Crankcase Emission Control System
This engine is equipped with a closed crankcase system. Blow-by gases are forced back to
the combustion chamber by the intake system. All exhaust gases exit through the exhaust
system.
86
Emission Control Systems
Exhaust Emission Control System
The emissions from the exhaust of this vehicle are controlled by engine design, including
factory-set fuel delivery and ignition. The engine and related components must be main-
tained at Polaris specifications to achieve optimal performance.
Engine idle speed is the only adjustment Polaris recommends that the operator perform. Any
other adjustments should be performed by an authorized Polaris dealer.
The emissions label is located on the front frame tube near the steering post.
Electromagnetic Interference
This spark ignition system complies with Canadian ICES-002.
This vehicle complies with the EMC requirements of European directives 97/24/EC and
2004/108/EC.
87
Maintenance
Periodic Maintenance Chart
Routine inspection and service are critical to the performance and reliability of your high
performance engine. Failure to perform the recommended maintenance procedures outlined
in the Periodic Maintenance Chart will result in forfeited warranty coverage as well as
decreased performance and reliability of the vehicle. If you're unable to perform the required
service and adjustment procedures, have a qualified dealer perform these operations.
Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the
need for replacement parts, use genuine Polaris parts available from your Polaris dealer.
Record maintenance and service in the Maintenance Log beginning on page 195.
88
Maintenance
Periodic Maintenance Chart
The recommended service intervals are based on average riding conditions. Vehicles sub-
jected to severe use must be inspected and serviced more frequently.
Severe Use Definition
• Frequent immersion in mud, water or sand
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold weather operation
89
Maintenance
Periodic Maintenance Chart
Improperly performing the procedures marked with a Q could result in component failure and cause an
accident, which may result in serious injury or death. Always have an authorized Polaris dealer perform
these services.
Maintenance Chart Key
X Perform these operations more often under severe use.
E Emission-related service (Failure to conduct this maintenance will not void the
emissions warranty but may affect emissions.)
Q Have an authorized Polaris dealer perform these services.
z Use Polaris Premium All Season Grease or grease conforming to NLGI No. 2.
WARNING
90
Maintenance
Periodic Maintenance Chart
Item Maintenance Interval
(whichever comes first)
Remarks
See
Page
Hours Calendar Fuel Used
Brake systems/brake fluid --
Pre-ride
--
Check each day before operating
the vehicle. Make adjustments as
needed. See the Pre-Ride
Checklist.
60
Tires -- --
Wheels/lug nuts -- --
Frame fasteners -- --
Coolant -- --
Fuel -- --
Engine oil -- --
Transmission oil -- --
Throttle -- --
Clutch system/clutch fluid -- --
Lights -- --
Engine stop switch -- --
Steering -- --
91
Maintenance
Periodic Maintenance Chart
X Perform these procedures more often for vehicles subjected to severe use
E Emission-Related Service
Q Have an authorized Polaris dealer perform these services
z Use Polaris Premium All Season Grease
Item Maintenance Interval
(whichever comes first)
Remarks
See
Page
Hours Calendar Fuel Used
in gallons (liters)
Air box sediment tubes -- Pre-ride -- Check each day before operating
the vehicle. Make adjustments as
needed. See the Pre-Ride Check-
list.
60
Headlamp -- --
Tail lamp/brake lamp -- --
A-arm ball joint -- --
Rear shaft assembly -- --
Oil and filter change
3 Break-in 5 (20)
Change the oil and filters 100
Oil screen/drain plug Clean screen and plug magnet 102
Idle speed Check idle speed setting 113
Engine mounting bolts Check torque --
E Valve clearance Check; adjust --
Outer clutch cover Check 6 mounting screw torques --
92
Maintenance
Periodic Maintenance Chart
Item Maintenance Interval
(whichever comes first)
Remarks
See
Page
Hours Calendar Fuel Used
in gallons (liters)
Brake pad wear 10 Monthly -- Inspect regularly 143
Battery 10 Monthly -- Check terminals; clean; test 129
XE Air filter 15 Weekly -- Inspect; clean; replace as needed 112
X Oil and filter change 15 6 M 26 (100) Perform initial oil change after first
3 hours of operation.
100
X Oil screen/drain plug 15 6 M 26 (100) Clean screen and plug magnet 102
Idle speed 15 6 M 26 (100) Check; adjust as needed 113
Engine mounting bolts 15 6 M 26 (100) Check torque --
Shift lever bolt 15 6 M 26 (100) Check torque --
E Valve clearance 15 6 M 26 (100) Check; adjust --
Clutches 30 6 M 52 (200) Check discs for wear --
E Spark plug 30 6 M 52 (200) Replace 122
93
Maintenance
Periodic Maintenance Chart
X Perform these procedures more often for vehicles subjected to severe use
E Emission-Related Service
Q Have an authorized Polaris dealer perform these services
z Use Polaris Premium All Season Grease
Item Maintenance Interval
(whichever comes first)
Remarks
See
Page
Hours Calendar Fuel Used
in gallons (liters)
Xz General lubrication 45 3 M 78 (300) Lubricate all fittings, pivots,
cables, etc.
--
Carburetor float bowl 45 6 M 78 (300) Drain bowl periodically and prior
to storage
114
QE Throttle cable/ETC switch 45 6 M 78 (300) Inspect; adjust; replace as needed 141
X Drive chain(s) 45 6 M 78 (300) Inspect daily; adjust; lubricate if
needed
146
XQ Brake pad replacement 45 6 M 78 (300) See your Polaris dealer --
Coolant strength 45 6 M 78 (300) Inspect strength seasonally 108
94
Maintenance
Periodic Maintenance Chart
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Fuel Used
in gallons (liters)
Xz Upper steering post (1) 45 6 M -- Inspect; tighten fasteners; grease after
washing ATV/driving in water
Xz Front A-Arms (2) 45 6 M -- Inspect; tighten fasteners; grease (also
after washing ATV or driving in water)
Xz Rear axle/eccentric (3) 30 3 M --
1
2
2
3
95
Maintenance
Periodic Maintenance Chart
X Perform these procedures more often for vehicles subjected to severe use
E Emission-Related Service
Q Have an authorized Polaris dealer perform these services
z Use Polaris Premium All Season Grease
Item Maintenance Interval
(whichever comes first)
Remarks
See
Page
Hours Calendar Fuel Used
in gallons (liters)
Clutch springs 60 12 M 104 (400) Check spring length (see dealer) --
Cam chain tensioner 60 12 M 104 (400) Check ratchet teeth for wear --
Coolant system 90 12 M 156 (600) Pressure test system annually --
X Cooling system hoses 90 12 M 156 (600) Inspect --
Radiator 90 12 M 156 (600) Inspect; clean external surface;
change coolant every 2 years
--
QE Fuel system 90 12 M 156 (600) Check for leaks at tank cap, lines,
fuel valve, filter, carburetor;
replace lines every two years
--
E Cylinder and piston 90 -- 156 (600) Inspect; measure; replace as
needed
--
Piston pin circlip groove 90 -- 156 (600) Visual inspection for wear --
96
Maintenance
Periodic Maintenance Chart
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Fuel Used
in gallons (liters)
E Compression ring 90 -- 156 (600) See your dealer or refer to the Dealer
Service Manual; measure ring gap and
replace if at or below service limit
E Oil scraper ring 90 -- 156 (600)
Camshaft 90 -- 156 (600) Visual inspection for wear
Valve spring cap 90 -- 156 (600) Visual inspection for wear
E Camshaft bearings 90 -- 156 (600) Replace
E Valve springs 90 -- 156 (600) See your dealer or refer to the Dealer
Service Manual; perform measurements;
replace as needed
E Valve seats/guides 90 -- 156 (600)
E Rocker arm rollers 90 -- 156 (600)
E Timing chain 90 -- 156 (600) Measure elongation; replace as needed
Cam chain tensioner 90 -- 156 (600) Check ratchet teeth for wear
E Bearings (connecting rod,
balance shaft, crankshaft
main)
90 -- 156 (600) Replace
Crankshaft run-out 90 -- 156 (600) Measure; adjust as needed
97
Maintenance
Periodic Maintenance Chart
X Perform these procedures more often for vehicles subjected to severe use
E Emission-Related Service
Q Have an authorized Polaris dealer perform these services
z Use Polaris Premium All Season Grease
Item Maintenance Interval
(whichever comes first)
Remarks
See
Page
Hours Calendar Fuel Used
in gallons (liters)
Oil pressure valve 90 -- 156 (600) Measure spring; replace as needed
Transmission 90 -- 156 (600) Check entire transmission/bearings for
wear; replace as needed
QE Ignition Timing -- 12 M -- Inspect; adjust as needed
Clutch fluid 90 12 M -- Bleed as needed; change yearly 138
QE Jet needle/needle jet 180 24 M -- Replace
Q Brake fluid 180 24 M -- Replace
Spark arrestor 300 36 M -- Clean out 124
Q Front/rear wheel bearings 300 36 M -- Inspect; replace as needed
Q Toe adjustment As required Inspect periodically; adjust when
parts are replaced
144
Headlight aim As required Adjust as needed 116
98
Maintenance
Engine Oil Recommendations
Always check and change the engine oil at the intervals outlined in the Periodic Maintenance
Chart beginning on page 87. Polaris recommends the use of Polaris PS-4 PLUS Performance
Synthetic 2W-50 4-cycle oil or a similar oil designed for use in 4-stroke manual clutch ATV
and motorcycle applications. Do not use Polaris PS-4 Performance Synthetic 10W-40 Oil.
Always use 2W-50.See page 172 for the part numbers of Polaris products.
NOTICE: Mixing brands or using a non-recommended oil may cause serious engine damage. Always
use the recommended oil. Never substitute or mix oil brands.
If the ATV is used year-round, check the oil level frequently. A rising oil level could indicate
the accumulation of contaminates such as water or excess fuel in the bottom of the crank-
case. Water in the bottom of the crankcase can lead to engine damage and must be drained.
Change the oil immediately if the oil level rises.
99
Maintenance
Engine Oil Level
Check the oil level before each use of the vehi-
cle. If the engine is cold, the oil level should be
visible at the lower edge of the sight glass. If the
engine is warm, the oil level should be visible
between the 1/2 and 3/4 levels in the sight glass.
1. Position the vehicle on a level surface.
2. View the oil level through the sight glass on
the right side of the vehicle.
3. Remove the fill plug and add the recom-
mended oil as needed.
4. Reinstall the fill plug.
Sight Glass
Fill Plug
Warm Level
Cold Level
100
Maintenance
Engine Oil Change
Always change the oil at the intervals outlined in the Periodic Maintenance Chart beginning
on page 87. Change the oil more frequently on vehicles subjected to severe use.
IMPORTANT: Perform the initial break-in oil change after the first three hours of operation. Always
change both oil filters and clean the oil screens whenever changing oil.
Before beginning the oil change procedure, read through the entire procedure. Be prepared to
complete the procedure entirely. Do not allow the vehicle to be without oil and filter over-
night. Always replace the oil and filters within a few hours of draining the oil.
NOTICE: If the ATV is left without oil in the system for extended periods, the oil pump may lose its
prime, which could result in engine damage.
101
Maintenance
Engine Oil Change
1. Position the vehicle on a level surface.
2. Start the engine. Allow it to idle for two to three minutes. Stop the engine.
3. Place a drain pan beneath the crankcase. Remove the drain plug. Allow the oil to drain
completely.
CAUTION! Hot oil can cause burns to skin. Do not allow hot oil to contact skin.
4. Clean the crankcase sealing surface and the
drain plug (with magnet) thoroughly.
5. Replace the sealing ring. Reinstall the drain
plug. Torque to 15 ft. lbs. (20 Nm).
Drain
Plug
102
Maintenance
Engine Oil Change
Cleaning the Short Oil Screen
Short Screen
Short Oil Screen
Plug
View from bottom of vehicle
Front
O-Rings
103
Maintenance
Engine Oil Change
Cleaning the Short Oil Screen
1. Remove the short oil screen plug at the bottom of the engine.
2. Remove the short oil screen. Clean the screen components thoroughly and blow well
with low pressure compressed air.
3. Check the O-rings. If damaged, install new O-rings.
4. Reinstall the screen to the plug.
5. Lubricate the threads and reinstall the plug. Torque to 7.5 ft. lbs. (10 Nm).
104
Maintenance
Engine Oil Change
Cleaning the Long Oil Screen
1. Remove the long screen plug, located
on the side of the engine near the engine
number.
2. Remove the oil screen. Clean the screen
thoroughly and blow with compressed
air.
3. Check the O-rings. If damaged, install
new O-rings.
4. Place the long oil screen on a pin-type
key or similar tool of about 12 inches
(300 mm) in length.
Plug
105
Maintenance
Engine Oil Change
Cleaning the Long Oil Screen
5. Insert the tool through the opening and into the bore of the opposite engine casing wall.
Push the oil screen into the casing as far as possible. Remove the tool.
NOTICE: An improperly installed oil screen will
function poorly and result in increased
engine wear. Install the screen securely
at the angle shown in the illustration.
6. Reinstall the plug. Torque to 11 ft. lbs.
(15 Nm).
106
Maintenance
Engine Oil Change
Changing Oil Filters
1. Place a drain pan under the engine.
2. Remove the four oil filter cover screws (1).
Remove the covers.
3. Using circle clip (snap ring) pliers, pull the
oil filter inserts (2) out of the housing.
4. Thoroughly clean the engine casing, filter
covers and sealing surfaces of the O-rings.
Check the O-rings. If damaged, install new
O-rings.
5. Fill each oil filter with oil. Install the long
filter at the front of the filter box. Install the
short filter at the rear of the box.
1
2
107
Maintenance
Engine Oil Change
Changing Oil Filters
6. Grease the filter cover O-rings (3).
7. Reinstall the covers and the screws. Tighten
screws to 4.5 ft. lbs. (6 Nm).
8. Remove the oil fill plug (4). Add 40 oz. (1.2
liters) of the recommended engine oil (see page
98). Reinstall the fill plug.
9. Start the engine. Allow it to idle for at least one
minute to fully distribute the new oil. Stop the
engine.
10. Check for leaks at all threaded connections and
at the oil filter covers.
11. View the oil level in the sight glass. Add oil as
needed to maintain the level as recommended
(see page 99).
3
4
108
Maintenance
Engine Cooling System
The engine coolant level is controlled or maintained by the recovery system. The recovery
system components are the recovery bottle, radiator filler neck, radiator pressure cap and
connecting hose.
To ensure that the coolant maintains its ability to protect the engine, we recommend that you
completely drain the cooling system every two years and add a fresh mixture of antifreeze
and water.
Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture
of high quality aluminum compatible anti-freeze/coolant and distilled water. Always follow
the manufacturer's mixing recommendations for the freeze protection required in your area.
Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. See
page 172 for the part numbers of Polaris products.
109
Maintenance
Engine Cooling System
Coolant Level
The recovery bottle is located on the right side of the
vehicle under the front fender. If the fluid level is vis-
ible at the bottom of the side panel, add 6 oz. (175 ml)
of coolant.
As coolant operating temperature increases, the
expanding (heated) excess coolant is forced out of the
radiator, past the pressure cap, and into the recovery
bottle. As engine coolant temperature decreases, the
contracting (cooled) coolant is drawn back up from
the tank, past the pressure cap, and into the radiator.
Some coolant level drop on new machines is normal,
as the system is purging itself of trapped air. Observe
coolant levels and maintain as recommended by add-
ing coolant to the recovery bottle.
110
Maintenance
Engine Cooling System
Radiator Coolant Level
If the recovery bottle has run dry, inspect the level in
the radiator and add coolant if necessary. The radiator
pressure cap is located on the left side of the vehicle.
CAUTION! Escaping steam can cause burns. Never
remove the pressure cap while the engine is warm or hot.
Always allow the engine to cool before removing the
pressure cap.
1. Remove the pressure cap.
2. Using a funnel, slowly add coolant as necessary
through the radiator filler neck.
3. Reinstall the pressure cap. Use of a non-standard
pressure cap will not allow the recovery system to function properly. Contact your dealer
for the correct replacement part.
Pressure Cap
111
Maintenance
Engine Cooling System
Cooling System Bleeding
Bleeding the cooling system is required only if the system has been drained for maintenance
and/or repair. Always allow the engine to cool sufficiently before removing the radiator pres-
sure cap.
1. Remove the pressure cap.
2. Using a funnel, slowly add the recommended coolant. Fill the radiator to the bottom of
the filler neck.
3. Reinstall the pressure cap.
4. Start the engine and allow it to idle for five minutes, or until operating temperature is
reached.
5. Stop the engine.
6. After the engine has cooled, add additional coolant to refill the radiator to the bottom of
the filler neck.
7. Operate the vehicle for 20 minutes, allow the engine to cool, then recheck the coolant
level in the radiator. Add coolant as needed.
112
Maintenance
Air Filter Systems
1. Remove the seat.
2. Release the airbox cover clips and remove the cover.
3. Remove the wing nuts securing the filter to the airbox.
4. Pull the filter assembly out of the air box. Note the placement of the rubber ring for rein-
stallation.
5. Wash the filter in soapy water, then rinse and let dry.
6. Apply a commercially available foam filter lubricant to the foam filter.
7. Reinstall the rubber ring properly to the filter assembly, and reinstall the filter into the air
box.
8. Secure the wing nuts and reinstall the air box cover.
9. Check the boots for cracks, deterioration, abrasion, or leaks. Replace as needed.
113
Maintenance
Carburetor
Normal wear from engine vibrations may cause the carburetor to supply an overly rich fuel
mixture. Replace the jet needle and the needle jet after every 180 hours of operation.
Idle Speed
Carburetor idle adjustments affect engine starting behavior. A proper idle speed of 1700-
1800 RPM will result in easier starting. If idle speed is unsatisfactory, make adjustments as
outlined on page 113.
Idle Speed
1. Position the vehicle on a level surface. Lock the parking
brake. Place the transmission in neutral.
2. Start the engine and allow it to idle for five minutes, or until
operating temperature is reached.
3. Turn the idle adjusting wheel (1) until idle speed reaches
1700-1800 RPM. If idle speed is unsatisfactory after per-
forming this procedure, see your Polaris dealer for informa-
tion about jetting changes.
1
114
Maintenance
Carburetor
Carburetor Draining
Drain the carburetor float bowl at the intervals outlined in the
Periodic Maintenance Chart beginning on page 87. Always
drain the bowl after exposure to wet conditions. Perform this
procedure when the engine is cool.
1. Turn the fuel valve off.
2. Place a suitable container under the carburetor to collect
drained fluid.
3. Remove the hex plug (1). Allow fluids to drain.
4. Reinstall the hex plug securely.
1
115
Maintenance
Carburetor Jetting
Carburetor re-jetting can be performed to compensate for altitude and/or temperature
changes. If the vehicle is to be operated at various altitudes and temperatures, certain adjust-
ments can be made to improve its operation and driveability. Above 6000 feet (1800 m) the
engine air/fuel mixture becomes overly rich. An engine loses approximately 3% of its power
for each 1000-foot (305 m) increase in elevation. Although this power cannot be regained,
changes to the carburetor and drive system can be made to allow more efficient operation.
Contact your dealer for altitude adjustments. Your dealer has the training and special tools
required to perform these modifications.
116
Maintenance
Lights
Headlight Adjustment
1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m)
from a flat wall.
2. Measure the distance from the floor to the center of the headlight and make a mark on
the wall at the same height.
3. Start the engine and turn the headlight switch to high beam.
2" (5 cm)
Lamp Center Height
25 ft. (7.6 m)
General Representation
117
Maintenance
Lights
Headlight Adjustment
4. Observe the headlight aim on the wall. The most
intense part of the headlight beam should be aimed
2" (5 cm) below the mark placed on the wall.
Include rider weight on the seat when measuring.
5. Loosen the pivot screw and adjust the beam to the
desired position.
6. Tighten the screw and torque to 27 in. lbs. (3 Nm).
Pivot Screw
118
Maintenance
Lights
Headlight Lamp Replacement
When servicing a halogen lamp, avoid touching the lamp with bare fingers. Oil from your
skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fingers do
touch a lamp, clean it with denatured alcohol.
1. Remove the wire harness connector from the back of the headlight.
2. Grasp the bulb housing and turn it counterclockwise to remove the bulb.
CAUTION! Hot components can cause burns to skin. Allow lamps to cool before servicing.
3. Apply dielectric grease to the socket and install the new bulb. Rotate firmly. The bulb
must be positioned so the harness installs into the lamp at outer side.
4. Reinstall the connector to the back of the headlight.
119
Maintenance
Lights
Headlight Assembly Replacement
1. Remove the front cover.
2. Remove the wire harness connector from the headlight.
3. Remove the two retaining brackets and the adjuster screw.
4. Remove the headlamp.
5. Install the new headlamp, placing it in the slots on the frame tabs. Secure the headlamp
with the retaining brackets.
6. Install the adjuster screw, leaving it loose so the headlight can be adjusted.
7. Connect the wire harness to the headlamp. Reinstall the front cover.
8. Adjust the lamp as needed (see page 116), then tighten the adjuster screw.
120
Maintenance
Front Cab/Side Panel Removal
The front cab and side panel assembly is removed in one
piece.
1. Remove the seat.
2. Remove the two front cover screws and remove the front
cover.
3. Remove the eight side panel screws (four on each side).
4. Remove the fuel cap.
5. Gently pull the side panel/cab assembly upward and
rearward.
6. Unplug the key switch and the indicator panel before
removing the cab.
7. To remove a side panel from the cab, remove the corre-
sponding push pin and slide the panel forward to disen-
gage the locking tabs.
Side Panel
Screws
Front Cover
Screws
121
Maintenance
Rear Cab Removal
1. Remove the seat.
2. Remove the two lower bolts (1)
on the rear fenders of the cab.
3. Remove the two bolts and
grommets (2) on the top of the
cab.
4. Remove the two bolts (3) at the
rear cab-to-front-cab joint.
5. Unplug the taillight connector.
6. Remove the cab.
1
3
2
122
Maintenance
Spark Plugs
Refer to the specifications section beginning on page 168 for recommended spark plug type
and gap.
NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use
Polaris-recommended spark plugs.
Spark plug condition is indicative of engine operation. The spark
plug firing end condition should be read after the engine has been
warmed up and the vehicle has been driven at higher speeds.
Immediately check the spark plug for correct color.
1. Access the spark plug at the right side of the engine.
2. Using the spark plug socket and a wrench, rotate counter-
clockwise to remove the spark plug.
CAUTION! A hot exhaust system and engine can cause burns. Wear
protective gloves when removing a spark plug for inspection.
3. After reinstalling the spark plug, torque to 14 ft. lbs. (19 Nm).
Spark
Plug
123
Maintenance
Spark Plugs
Normal Plug
The normal insulator tip is gray, tan or light brown. There will be few combustion deposits.
The electrodes are not burned or eroded. This indicates the proper type and heat range for the
engine and the service.
The tip should not be white. A white insulator tip indicates overheating, caused by use of an
improper spark plug or incorrect carburetor/throttle body adjustments.
Wet Fouled Plug
The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a
carbon layer over the entire nose. Generally, the electrodes are not worn. General causes of
fouling are excessive oil, use of non-recommended oil, improper use of the choke, or incor-
rect carburetion adjustments.
124
Maintenance
Spark Arrestor Clean-Out
Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or
death. The exhaust system can get extremely hot. Do not perform service on the spark arrestor while
the system is hot. Allow components to cool sufficiently before proceeding.
Remove any combustible materials from the area. Wear eye protection and leather work gloves. Do not
stand behind or in front of the vehicle while purging. Never run the engine in an enclosed area. Never
go under the vehicle while it's inclined.
WARNING
125
Maintenance
Spark Arrestor Clean-Out
To remove accumulated carbon, clean the
spark arrestor at the intervals recommended
in the Periodic Maintenance Chart beginning
on page 87.
1. Remove the retaining screw and remove
the arrestor from the end of the muffler.
2. Use a non-synthetic brush to clean the
arrestor screen. A synthetic brush may
melt if components are warm. If neces-
sary, blow debris from the screen with
compressed air.
3. Inspect the screen for wear and damage.
Replace a worn or damaged screen.
4. Reinstall the arrestor. Torque screws to
5-7 ft. lbs. (7-9 Nm).
Arrestor
Retaining
Screw
Screen
Muffler
126
Maintenance
Vehicle Immersion
If the vehicle tips or overturns in water deeper than the footpeg level, or if the engine stops
during or after operating in water, restarting WILL result in serious engine damage. Trans-
port the vehicle to your dealer for service before restarting the engine. If this is not possible,
follow the vehicle immersion inspection and drying procedures outlined below. This proce-
dure will allow short-term operation only to drive the ATV to a trailer or towing vehicle.
Do not perform the following procedures if you don't feel completely capable, or if you sus-
pect that water has entered the fuel tank (likely if the water was deep or if the ATV over-
turned). Tow or trailer the ATV to your dealer for immediate service.
127
Maintenance
Vehicle Immersion
1. Turn the fuel valve off.
2. Drain water from the air box and clean the air filter. See page 112.
3. Drain the carburetor bowl. See page 114.
4. Remove the spark plug. See page 122.
WARNING! Fluids will be ejected through the spark plug hole and may cause serious injury to face or
other body parts. Wear protective eyewear and stand clear of the spark plug while performing the
following steps.
5. Intermittently and briefly touch the starter button in half-second intervals to SLOWLY
rotate the engine three or four times. Fluids will eject from the spark plug hole.
(continued on following page)
128
Maintenance
Vehicle Immersion
6. Press and hold the starter button for 10 second intervals for about one minute or until
water vapor is no longer ejecting from the spark plug hole.
7. Check the oil level. If the level is higher than the pre-ride inspection level, water has
entered the crankcase. Do not start the engine. Transport the vehicle to your dealer for
inspection and service. If the oil level is unchanged from the pre-ride inspection level,
replace the spark plug, start the engine and move the ATV promptly to a trailer or towing
vehicle.
NOTICE: If water isn't removed promptly from a submerged ATV, rust will form in precision
components, gears, bearings, the cylinder and other areas and result in serious engine
damage. Always see your dealer promptly after an ATV has been submerged.
129
Maintenance
Battery
Improperly connecting or disconnecting battery cables can result in an explosion and cause serious
injury or death. When removing the battery, always disconnect the negative (black) cable first. When
reinstalling the battery, always connect the negative (black) cable last.
The sealed battery is already filled with electrolyte and has been sealed and fully charged at
the factory. Never pry the sealing strip off or add any other fluid to this battery.
Keep the battery terminals and connections 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 water and dry off with clean shop towels. Coat
the terminals with dielectric grease or petroleum jelly.
WARNING
130
Maintenance
Battery Storage
Whenever the vehicle is not used for a period of three months or more, remove the battery
from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place.
Check battery voltage each month during storage and recharge as needed to maintain a full
charge.
Battery Removal
1. Remove the rear cab (see page 120).
2. Disconnect the hold-down strap securing the battery in position.
3. Disconnect the black (negative) battery cable first.
4. Disconnect the red (positive) battery cable last.
5. Lift the battery out of the ATV.
131
Maintenance
Battery Installation
Always install a fully charged battery. Using a new battery that has not been fully charged
can damage the battery and result in a shorter life. It can also hinder vehicle performance. If
recharging is necessary, use a .5 amp battery charger.
1. Place the battery in the battery holder.
2. Connect and tighten the red (positive) cable first.
3. Connect and tighten the black (negative) cable last.
4. Attach the hold-down strap.
5. Reinstall the rear cab.
6. Verify that cables are properly routed.
132
Maintenance
Battery Charging (Sealed Battery)
On a sealed battery, the sealing strip cannot be removed. Use a voltmeter or multimeter to
measure DC voltage. A fully charged battery will register 12.8 V or higher. If the voltage is
less than 12.8 volts, recharge the battery.
WARNING! An overheated battery could explode, causing severe injury or death. Always watch
charging times carefully. Stop charging if the battery becomes very warm to the touch. Allow it to cool
before resuming charging.
The battery may be recharged without
removing it from the vehicle. Attach cables
in the following order:
1. Attach the positive (+) cable clamp to
the solenoid lead (directly wired to the
battery).
2. Attach the negative (-) cable clamp to
the negative (-) battery terminal.
2. Negative (-)
Terminal
1. Solenoid Lead
133
Maintenance
Battery Charging (Sealed Battery)
The Polaris Battery Tender battery charger can be left connected during the storage period
and will automatically charge the battery if the voltage drops below a pre-determined point.
If the battery fails to recharge during vehicle operation, check voltage regulator connections.
See your Polaris dealer for inspection of the voltage regulator and generator.
When using an automatic charger such as the Polaris Battery Tender, refer to the manufac-
turer's instructions for recharging. When using a constant current charger, use the guidelines
on the following page for recharging.
134
Maintenance
Battery Charging (Sealed Battery)
Always verify battery condition before and 1-2 hours after the end of charging.
State of
Charge
Voltage Action
Charge Time
(Using constant current
charger @ standard amps
specified on top of battery)
100% 12.8-13.0 volts None, check at 3 months from
date of manufacture
None required
75%-100% 12.5-12.8 volts May need slight charge, if no
charge given, check in 3
months
3-6 hours
50%-75% 12.0-12.5 volts Needs charge 5-11 hours
25%-50% 11.5-12.0 volts Needs charge At least 13 hours, verify
state of charge
0%-25% 11.5 volts or less Needs charge with desulfating
charger
At least 20 hours
135
Maintenance
Tires
Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed
tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Always
follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle.
Always use original equipment size and type when replacing tires. Always ensure that all nuts are
torqued to specification.
Tire Tread Depth
Always replace tires when tread depth is
worn to 1/8" (3 mm) or less.
WARNING
1/8" (3 mm)
136
Maintenance
Wheel Nut Torque Specifications
Check the wheel nut torques occasionally and when they've been loosened for maintenance.
Wheel Hub Tightening
Front wheel bearing tightness and spindle nut retention are critical component operations.
All service must be performed by your authorized Polaris dealer.
Wheel Removal
1. Stop the engine. Place the transmission in gear. Lock the parking brake.
2. Loosen the wheel bolts slightly.
3. Elevate the side of the vehicle by placing a suitable stand under the frame.
4. Remove the wheel nuts and remove the wheel.
Bolt Location & Size Torque Specification
Front 3/8" 30-35 ft. lbs. (40-47 Nm)
Rear 3/8" 30-35 ft. lbs. (40-47 Nm)
137
Maintenance
Wheel Installation
1. Place the transmission in gear. Lock the parking
brake.
2. Place the wheel on the wheel hub with the valve
stem toward the outside and rotation arrow on the
tire pointing toward forward rotation. Never
install the rim with the valve stem to the inside of
the vehicle.
3. Install the wheel bolts and finger tighten them.
4. Lower the vehicle to the ground.
5. Securely tighten the bolts to specification. See
page 136.
Valve
Stem
138
Maintenance
Clutch System Bleeding
Always bleed the clutch system at the intervals out-
lined in the Periodic Maintenance Chart beginning on
page 87. Always bleed the clutch system any time the
clutch lever feels unresponsive.
Always use the recommended fluid when bleeding
the clutch system. See page 43.
1. Position the vehicle on a level surface. Turn the
handlebar until the master cylinder is in a hori-
zontal position.
2. Remove the two cover screws, the cover and the
rubber boot.
3. Fill a bleeder syringe (1) with the recommended
hydraulic clutch oil.
1
2
3
139
Maintenance
Clutch System Bleeding
4. Remove the bleeder screw (2) from the slave cylinder.
5. Press fluid into the system until the fluid runs out of the hole (3) in the master cylinder
without producing bubbles. Extract fluid from the master cylinder during the process to
prevent overflowing.
6. When finished, remove the bleeder syringe.
7. Reinstall the bleeder screw.
8. Add or remove fluid as needed to maintain the level 4mm below the top edge of the mas-
ter cylinder reservoir.
9. Reinstall the cover, boot and screws securely.
140
Maintenance
Throttle Lever Freeplay
Periodically check throttle lever freeplay.
Maintain freeplay between 1/16" and 1/8"
(1.5 - 3 mm).
If adjustments are needed, use the procedure
on page 141.
1/16" - 1/8"
(1.5 - 3 mm)
141
Maintenance
Throttle Cable Freeplay Adjustment
Improper adjustment of throttle cable freeplay can result in loss of control, which could result in serious
injury or death. Polaris recommends that this procedure be performed by a Polaris dealer to ensure
that it's done correctly. Mechanically knowledgeable persons who perform this procedure must follow
the adjustment procedures exactly.
1. Locate the throttle cable at the handlebar.
2. Slide the boots off the inline cable adjuster
sleeve and loosen the locking nut.
3. Turn the adjuster until 1/16" to 1/8" (1.5-3 mm)
freeplay is achieved at the thumb lever. While
adjusting freeplay, be sure to flip the throttle
lever back and forth.
4. Tighten the locknut and slide the boots over the cable adjuster until they touch at the
midpoint of the adjuster.
WARNING
Boot Boot
Sleeve
Locking Nut
142
Maintenance
Brakes
Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the
fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm
should be replaced. To ensure proper diaphragm operation, always fill the reservoir as
needed whenever the cover is loosened or removed. Do not overfill.
WARNING! An over-full master cylinder may cause brake drag or brake lock-up, which could result in
serious injury or death. Maintain brake fluid at the recommended level. Do not overfill.
Both brakes are self-adjusting, but the following checks are recommended to keep the brake
systems in good operating condition. Check more often if brakes are used heavily under nor-
mal operation.
143
Maintenance
Brakes
1. Always maintain brake fluid at the recommended level. See
pages 48-49.
2. Check the brake system for fluid leaks.
3. Check the brakes for excessive travel or spongy feel.
4. Check the friction pads for wear, damage and looseness.
5. Check the security and surface condition of the disc.
6. Inspect the rear brake disc spline and pad wear surface for
excessive wear. Pads should be changed when worn to 3/64"
(1 mm).
3/64" (1 mm)
144
Maintenance
Toe Alignment
Use the following procedure to check the toe alignment of the vehicle. The vehicle is
designed for a neutral toe setting.
WARNING! Severe injury or death can result from improper toe alignment and adjustment. Do not
attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized
Polaris dealer.
1. Position the vehicle on a level surface.
2. Place the handlebars in a straight-ahead position. Use tie straps to secure the handlebars
to the rear grab bar so they can't move.
145
Maintenance
Toe Alignment
3. Tie a length of string between two stands as
shown in the illustration. Position the stands so
that the string is flush with the side of the rear
tire. If available, you may use a long straight-
edge instead of string.
4. Measure the distance from the string to the rim
at the front (1) and rear (2) of the front rim.
The rear measurement should be between 0"
and 1/16" (0-1.5 mm) more than the front mea-
surement.
5. Repeat the measurement procedure on the
other side of the vehicle.
6. If you discover improper alignment, see your
Polaris dealer for service.
2
Stand
String
1
146
Maintenance
Chain Tension Inspection
Check the amount of chain slack by moving the
vehicle slightly forward to remove slack at the top
side of the chain.
NOTICE: Never adjust or operate the vehicle with the
rear drive chain too loose or too tight. Severe
damage to the transmission and drive
components can result. Chain tension must be
inspected with the swing arm in the position
shown in the illustration so that the axle, swing
arm pivot and drive sprocket are aligned
horizontally (2).
The chain has a press-on master link. A chain tool
must be used if it's necessary to remove the chain
for service.
2
3
1
147
Maintenance
Chain Tension Inspection
1. Collapse the suspension with an adjustable (buckle type) trailer tie down strap (1). Fas-
ten the strap around the axle and rear bumper tube.
2. Tighten the strap until a straight line (2) can be drawn from the axle to the transmission
output shaft, intersecting the swing arm pivot. This establishes the tightest chain posi-
tion.
3. At the center point of the chain (3) deflection should be 1/4" - 3/8" (6-9 mm). Use the
procedure on the following page if the chain needs adjustment.
148
Maintenance
Chain Tension Adjustment
1. Loosen the two eccentric locking bolts. Refer to the illustration on the following page.
2. Insert a pin punch into the eccentric axle housing.
3. Roll the vehicle slightly to adjust chain slack to the proper dimension.
4. Tighten the eccentric locking bolts to 35 ft. lbs. (47.5 Nm).
149
Maintenance
Chain Tension Adjustment
Step 1
Step 2
Proper splicelink clip
opening position
150
Maintenance
Handlebar Adjustment
Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can
cause limited steering or loosening of the handlebars, resulting in loss of control. Follow the adjustment
procedures exactly, or see your Polaris dealer for service.
The handlebars can be adjusted for rider preference.
1. Loosen the four handlebar bolts.
2. Adjust the handlebar to the desired height. Be
sure the handlebars do not contact the gas tank or
any other part of the machine when turned fully
to the left or right.
3. Torque the two front bolts to 10-12 ft. lbs. (14-16
Nm), then torque the two rear bolts. A gap of up
to 1/8" (3 mm) will remain at the rear bolts.
WARNING
Loosen
bolts
151
Maintenance
Steering Inspection
Check the steering assembly periodically for loose nuts and bolts. If loose nuts and bolts are
found, or if you notice any freeplay in the steering post, see your Polaris dealer for service
before operating the vehicle.
Camber and Caster
The camber and caster are non-adjustable.
152
Maintenance
Suspension Settings
Use a flat-blade screwdriver to make damping adjustments. When the adjuster screw is
turned clockwise until it stops, the damping is in the fully closed position.
Rear Shock (Standard and Limited Edition)
Front Shock (Limited Edition)
Setting Compression Damping Rebound Damping
Softest 20 clicks from closed 24 clicks from closed
Factory 10 clicks from closed 16 clicks from closed
Firmest 2 clicks from closed 2 clicks from closed
Setting Compression
Softest 20 clicks from closed
Factory 10 clicks from closed
Firmest 2 clicks from closed
153
Maintenance
Front Suspension
Compression Damping (Limited Edition)
To adjust the front suspension compression damping, use the adjustment procedures outlined
for the rear suspension compression damping on page 157.
Spring Preload
The front suspension preload may be adjusted to suit different riding conditions and operator
weight.
See page 154.
154
Maintenance
Front Suspension
Spring Preload
1. Raise and safely support the front of the vehicle off the
ground to allow the suspension to fully extend.
2. Loosen the jam nut and back it away from the adjusting
ring.
3. Turn the adjusting ring to the left (1) to increase preload
for a stiffer ride. Turn the adjusting ring to the right (2) to
decrease preload for a softer ride. See Suspension Set-
tings on page 152.
WARNING! Uneven adjustment may cause poor handling of the
ATV, which could result in an accident. Always adjust both the left
and right spring preloads equally or have your Polaris dealer
perform the adjustments.
4. Tighten the jam nut firmly against the adjuster ring.
2
1
Adjusting
Ring
155
Maintenance
Rear Suspension
The rear suspension spring preload, shock rebound damping
and shock compression damping may be adjusted to suit
different riding conditions and operator weight.
Spring Preload
1. Raise and safely support the rear of the vehicle off the
ground to allow the suspension to fully extend.
2. Loosen the jam nut and back it away from the adjusting
ring.
3. Turn the adjusting ring to the left (1) to increase pre-
load. Turn the ring to the right (2) to decrease preload.
See Suspension Settings on page 152.
4. Tighten the jam nut firmly against the adjuster ring.
21
Jam
Nut
Adjusting
Ring
156
Maintenance
Rear Suspension
Rebound Damping
Use a flat-blade screwdriver to make damping adjustments.
The rebound damping is factory set at 16 clicks from fully
closed. See Suspension Settings on page 152.
1. Locate the rebound damping clicker drum between the
lower spring seat and the lower shock mount.
2. Turn the clicker counter-clockwise (1) to decrease the
rebound damping. Turn the clicker clockwise (2) to
increase rebound damping.
Clicker
2
1
157
Maintenance
Rear Suspension
Compression Damping
Use a flat-blade screwdriver to make damping adjust-
ments. The factory setting is at 10 clicks from fully
closed. See Suspension Settings on page 152.
The compression damping clicker is located on top of
the shock reservoir, under the right rear fender.
1. Turn the clicker clockwise (1) to increase compres-
sion damping.
2. Turn the clicker counter-clockwise (2) to decrease
compression damping.
Clicker
1
2
158
Maintenance
Cleaning
Keeping your vehicle clean will not only improve its appearance but it can also extend the
life of various components.
NOTICE: High water pressure may damage components. Polaris recommends washing the vehicle by
hand or with a garden hose, using mild soap.
Certain products, including insect repellents and chemicals, will damage plastic surfaces.
Do not allow these types of products to contact the vehicle.
Washing the Vehicle
The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild
soap and water.
1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts
last.
2. Rinse with clean water frequently.
3. Dry surfaces with a chamois to prevent water spots.
159
Maintenance
Cleaning
Washing the Vehicle
Washing Tips
• Avoid the use of harsh cleaners, which can scratch the finish.
• Do not use a power washer to clean the vehicle.
• Do not use medium to heavy duty compounds on the finish.
• Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and
pads may contain dirt particles that will scratch the finish.
160
Maintenance
Cleaning
Washing the Vehicle
If a high pressure water system is used for cleaning (not recommended), exercise extreme
caution. The water may damage components and could remove paint and decals. If warning
and safety labels are damaged, contact your Polaris dealer for free replacement. Avoid direct-
ing the water stream at the following items:
• Wheel bearings
• Electrical components and wiring
• Transmission seals
•Brakes
• Cab and body panels
• Labels and decals
Grease all zerk fittings immediately after washing. Allow the engine to run for a while to
evaporate any water that may have entered the engine or exhaust system.
161
Maintenance
Polishing
Polaris recommends the use of common household aerosol furniture polish for polishing the
finish on your Polaris vehicle. Follow the instructions on the container.
Polishing Tips
• Avoid the use of automotive products, some of which can scratch the finish of your vehi-
cle.
• Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and
pads may contain dirt particles that will scratch the finish.
162
Maintenance
Storage
NOTICE: Starting the engine during the storage period will disturb the protective film created by
fogging and damage could occur. Never start the engine during the storage period.
Exterior
Make necessary repairs and clean the vehicle as recommended. See page 158.
Battery Storage
Refer to pages 129-134 for battery storage and battery charging procedures.
163
Maintenance
Storage
Engine Oil
Change the oil and both filters. Clean the oil screens. See page 100.
Air Filter / Air Box
Inspect and clean (or replace) the air filter. Clean the air box. Drain the sediment tube.
Fluid Levels
Inspect fluid levels. Change fluids as recommended in the Periodic Maintenance Chart
beginning on page 87.
• Transmission Oil
•Engine Oil
• Coolant (test strength/fill)
•Brake Fluid
• Clutch Fluid
164
Maintenance
Storage
Stabilize the Fuel
1. Fill the fuel tank with fuel.
2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instruc-
tions on the container for the recommended amount. Carbon Clean removes water from
fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and
exhaust systems. It also prevents bacterial growth and promotes better starting after the
storage period.
3. Start the engine and allow it to run for 15-20 minutes so the stabilizer can disperse
through the fuel in the tank and carburetor.
4. Stop the engine. Turn the fuel valve off.
5. Start the engine. Allow the engine to operate until it stops.
6. Drain the carburetor bowl. See page 114.
7. Remove the spark plug. Pour approximately 5 cc of engine oil into the cylinder through
the opening. Using the start button, rotate the engine several times to distribute the oil
onto the cylinder walls. Reinstall the spark plug. Torque to specification.
165
Maintenance
Storage
Lubricate
Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Main-
tenance Chart beginning on page 87.
Storage Area/Covers
1. Make sure tire pressure is at specification.
2. Be sure the storage area is well ventilated.
3. Using suitable supports under the frame, raise the vehicle slightly so that the tires are not
touching the ground.
4. Cover the vehicle with an appropriate cover. Do not use plastic or coated materials. They
do not allow enough ventilation to prevent condensation, and may promote corrosion
and oxidation.
166
Maintenance
Transporting the ATV
1. Stop the engine.
2. Place the transmission in first gear.
3. Lock the parking brake.
4. Remove the key to prevent loss during transporting.
5. Secure the fuel cap, oil cap and seat.
6. Turn the fuel valve off.
7. Always tie the frame of the ATV to the transporting unit securely with suitable straps or
rope.
167
Maintenance
Transporting the ATV
168
Specifications
Outlaw 450 MXR
Max. Weight Capacity 215 lbs./98 kg Pilot Jet #45
Dry Weight 360 lbs./163 kg Main Jet #138
Fuel Capacity 3.1 gal./11.8 l Clip Position 3
Overall Length 71.5 in./182 cm Jet Needle OBDVR
Overall Width 47 in./119 cm Alternator Output 200 w @ 3000 RPM
Overall Height 45 in./114 cm Compression Ratio 11:1
Wheelbase 50.5 in./128 cm Starting System Electric
Ground Clearance 5 in./13 cm Carburetor Keihin FCR-MX 39mm
Min. Turning Radius 67 in./170 cm Ignition System CDI
Engine Oil Capacity 1.7 qts./1.6 l Ignition Timing 25° +/- 3° @ 3500 RPM in
neutral
Coolant Capacity 2.25 qts./2.1 l Spark Plug Type NGK DCPR8E
Engine ES45KLE Spark Plug Gap 0.6 mm / .024 in.
Displacement 448 cc Lubrication System Dry Sump/Internal Reservoir
Bore x Stroke 89 x 72 mm
169
Specifications
Outlaw 450 MXR Jetting Chart
Outlaw 450 MXR
Driving System Type Rear Two-Wheel Drive Tire Size - Front 20 x 6R10
Shift Type 5-Speed Manual Shift Tire Size - Rear 18 x 10R9
Primary Ratio 2.516 Tire Pressure - All 4 psi/27.6 KPa
Gear Ratio - 1st 2.500 Front Brake Hydraulic Disc, Dual Bore
Gear Ratio - 2nd 1.941 Rear Brake Hydraulic Disc
Gear Ratio - 3rd 1.579 Parking Brake Hydraulic lock, front wheel
Gear Ratio - 4th 1.333 Headlight Dual Beam (55w/60w)
Gear Ratio - 5th 1.130 Taillight LED
Gear Ratio - Reverse 2.429 Brakelight LED
ALTITUDE
Meters (Feet)
AMBIENT TEMPERATURE
Below 40° F (Below 5° C) +40°F and above (+5°C and above)
0-1800 (0-6000) Main Jet: 148
Needle Clip Position: #3
Main Jet: 138
Needle Clip Position: #3
1800-3700
(6000-12000)
Main Jet: 138
Needle Clip Position: #2
Main Jet: 125
Needle Clip Position: #2
170
Specifications
Outlaw 525 S
Max. Weight Capacity 215 lbs./98 kg Pilot Jet #45
Dry Weight 370 lbs./168 kg Main Jet #138
Fuel Capacity 3.1 gal./11.8 l Clip Position 4
Overall Length 71.5 in./182 cm Jet Needle OBDVS
Overall Width 47.5 in./121 cm Alternator Output 200 w @ 3000 RPM
Overall Height 45 in./114 cm Compression Ratio 11:1
Wheelbase 50.5 in./128 cm Starting System Electric
Ground Clearance 5 in./13 cm Carburetor Keihin FCR-MX 39mm
Min. Turning Radius 67 in./170 cm Ignition System CDI
Engine Oil Capacity 1.7 qts./1.6 l Ignition Timing 25° +/- 3° @ 3500 RPM in
neutral
Coolant Capacity 2.25 qts./2.1 l Spark Plug Type NGK DCPR8E
Engine ES51KLE Spark Plug Gap 0.6 mm / .024 in.
Displacement 510 cc Lubrication System Dry Sump/Internal Reservoir
Bore x Stroke 95 x 72 mm
171
Specifications
Outlaw 525 S Jetting Chart
Outlaw 525 S
Driving System Type Rear Two-Wheel Drive Tire Size - Front 21 x 7R10
Shift Type 5-Speed Manual Shift Tire Size - Rear 20 x 11R9
Primary Ratio 2.516 Tire Pressure - All 4 psi/27.6 KPa
Gear Ratio - 1st 2.500 Front Brake Hydraulic Disc, Dual Bore
Gear Ratio - 2nd 1.941 Rear Brake Hydraulic Disc
Gear Ratio - 3rd 1.579 Parking Brake Hydraulic lock, front wheel
Gear Ratio - 4th 1.333 Headlights Dual Beam (55w/60w)
Gear Ratio - 5th 1.130 Taillight LED
Gear Ratio - Reverse 2.429 Brakelight LED
ALTITUDE
Meters (Feet)
AMBIENT TEMPERATURE
Below 40° F (Below 5° C) +40°F and above (+5°C and above)
0-1800 (0-6000) Main Jet: 148
Needle Clip Position: #4
Main Jet: 138
Needle Clip Position: #4
1800-3700
(6000-12000)
Main Jet: 138
Needle Clip Position: #3
Main Jet: 128
Needle Clip Position: #3
172
Polaris Products
Part Number Description
Engine Lubricant
2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt.)
2876245 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal.)
Grease / Specialized Lubricants
2871312 Grease Gun Kit, Premium All Season (3 oz.)
2871322 Premium All Season Grease (3 oz. cartridge)
2871423 Premium All Season Grease (14 oz. cartridge)
2871460 Starter Drive Grease (2 oz.)
2871329
Dielectric Grease (Nyogel
t)
2872073 Chain Lube, Aerosol (6.25 oz.)
2872348 Chain Lube, Aerosol (16 oz.)
1350046 Rear Shaft Grease (30 g)
173
Polaris Products
Part Number Description
Coolant
2871323 60/40 Coolant (gal.)
2871534 60/40 Coolant (qt.)
Additives / Miscellaneous
2871326 Carbon Clean Plus (12 oz.)
2870652 Fuel Stabilizer (16 oz.)
2872189 DOT4 Brake Fluid (12 oz.)
2876335 Hydraulic Clutch Oil (qt.)
174
Troubleshooting
See your Polaris dealer if you're unable to identify solutions using the following charts.
Engine Turns Over, Fails to Start
Possible Cause Solution
Out of fuel Turn the fuel valve to reserve, refuel
Water is present in carburetor or fuel supply Clean carburetor and/or drain fuel system and refuel
Fuel valve is turned off Turn the fuel valve on
Engine is cold Use choke to start a cold engine
Interrupted fuel supply Turn the fuel valve off; remove the fuel hose at the
carburetor and place in a drain pan; turn the fuel valve
on.
• If fuel leaks out, clean the carburetor.
• If no fuel leaks out, clean the fuel valve.
Clogged fuel valve or filter Inspect and clean or replace
Old or non-recommended fuel Replace with new fuel
Fouled or defective spark plug(s) Inspect and clean or replace plug(s)
Incorrect spark plug gap Adjust gap to specification
175
Troubleshooting
Engine Turns Over, Fails to Start
Possible Cause Solution
No spark to spark plug Inspect, clean and/or replace spark plugs
See your Polaris dealer
Overuse of choke/flooded engine Engage starter 2 times for 5 seconds each, then restart.
If engine fails to start, inspect, clean and/or replace
spark plugs.
Low battery voltage Recharge battery to 12.8 VDC
Ignition system or other mechanical failure See your Polaris dealer
Throttle ETC switch not opening Adjust throttle freeplay
The plug connection of the CDI-unit, pulse generator
or ignition coil has oxidized
Clean the plug connection and treat with contact spray
176
Troubleshooting
Engine Doesn’t Turn Over
Engine Pings or Knocks
Possible Cause Solution
Fuseable link See Polaris dealer for replacement
Low battery voltage Recharge battery to 12.8 VDC
Loose battery connections Check all connections and tighten
Loose solenoid connections Check all connections and tighten
Possible Cause Solution
Poor quality or low octane fuel Replace with recommended fuel
Incorrect ignition timing See your Polaris dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
177
Troubleshooting
Engine Backfires
Possible Cause Solution
Weak, fouled or defective spark plug Inspect, clean and/or replace spark plugs
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
Old or non-recommended fuel Replace with new fuel
Exhaust leak Inspect system for leaks; see your Polaris dealer
Incorrectly installed spark plug wire See your Polaris dealer
Incorrect ignition timing See your Polaris dealer
Mechanical failure See your Polaris dealer
178
Troubleshooting
Engine Runs Irregularly, Stalls or Misfires
Possible Cause Solution
Fouled or defective spark plug Inspect, clean and/or replace spark plug
Worn or defective spark plug wire See your Polaris dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plug
Loose ignition connections Check all connections and tighten
Defective ignition system See your Polaris dealer
Water present in fuel Replace with new fuel
Low battery voltage Recharge battery to 12.8 VDC or replace
Kinked or plugged fuel vent line Inspect and replace
Old or non-recommended fuel Replace with recommended fuel
179
Troubleshooting
Engine Runs Irregularly, Stalls or Misfires
Possible Cause Solution
Clogged air filter Inspect and clean or replace
Electronic throttle control malfunction See your Polaris dealer
Incorrect idle adjustment Adjust idle speed or see your Polaris dealer
Clogged idle jet Disassemble carburetor and clean the jets
Other mechanical failure See your Polaris dealer
180
Troubleshooting
Engine Runs Irregularly, Stalls or Misfires
Possible Lean Fuel Mixture Cause Solution
Low or contaminated fuel Add or change fuel, clean the fuel system
Low octane fuel Replace with recommended fuel
Old or non-recommended fuel Replace with recommended fuel
Clogged fuel valve screen See your Polaris dealer
Incorrect jetting See your Polaris dealer
Possible Rich Fuel Mixture Cause Solution
Overuse of choke Inspect, clean and/or replace spark plugs
Fuel is very high octane Replace with recommended octane fuel
Incorrect jetting See your Polaris dealer
Plugged, dirty or wet air filter Clean pre-filter, replace main filter as needed
181
Troubleshooting
Engine Fails to Reach High RPM
Engine Uses Excessive Oil
Possible Cause Solution
Worn or dirty needle valve Clean and/or replace needle valve
Loose carburetor jets Tighten jets
Faulty ignition timing See your Polaris dealer
Possible Cause Solution
Bent engine ventilation hose Install a new hose
Excessive oil in system Check oil level, maintain at recommended level
Use of non-recommended oil (too thin) Replace with a recommended oil
182
Troubleshooting
Engine Stops or Loses Power
Possible Cause Solution
Out of fuel Turn the fuel valve to reserve, refuel
Interrupted fuel supply Clean fuel system and carburetor
Clogged, dirty or wet air filter Inspect and clean or replace
Electronic throttle control malfunction See your Polaris dealer
Other mechanical failure See your Polaris dealer
Overheated engine Clean radiator screen and core if equipped
Clean engine exterior
Check oil level, maintain at recommended level
See your Polaris dealer
183
Troubleshooting
Engine Stops or Loses Power
Possible Cause Solution
Kinked or plugged fuel vent line Inspect and replace
Water present in fuel Replace with new fuel
Overuse of choke Inspect, clean and/or replace spark plugs
Fouled or defective spark plug Inspect, clean and/or replace spark plugs
Worn or defective spark plug wire See your Polaris dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
Loose ignition connections Check all connections and tighten
Low battery voltage Recharge battery to 12.8 VDC
Old or non-recommended fuel Replace with recommended fuel
184
Troubleshooting
Engine Overheats
Possible Cause Solution
Debris lodged in radiator screen Remove and clean the screen
Plugged radiator Use a garden hose to flush any debris from the radia-
tor fins. NOTE: High pressure washers can deform the
radiator fins and reduce cooling efficiency.
Insufficient coolant Check levels and fill as needed; check for leaks
Insufficient air flow due to slow operation Operate at a faster speed to increase air flow
Excessive oil in system Check oil level, maintain at recommended level
Cooling system has not been bled Bleed the cooling system
Foam has formed in cooling system Drain and replace coolant with recommended coolant
Bent cooling hose Shorten or replace hose
Defective thermostat or thermoswitch See your Polaris dealer
Blown fan fuse or defective fan Replace fuse and check fan for proper operation or see
your Polaris dealer
185
Troubleshooting
Engine Fails to Reach Full Power
Possible Cause Solution
Interrupted fuel supply Clean fuel system and carburetor
Float leaks Replace the float
Clogged, dirty or wet air filter Inspect and clean or replace
Faulty exhaust system Check system for damage; see your Polaris dealer
Valve gap is too small Adjust valve gap
Faulty ignition timing See your Polaris dealer
186
Warranty
LIMITED WARRANTY
Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all
components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also
gives a one year limited warranty on the final drive chain for failure due to defects. This warranty covers the parts
and labor charges for repair or replacement of defective parts which are covered by this warranty. This warranty
begins on the date of purchase. This warranty is transferable to another consumer during the warranty period
through a Polaris dealer.
REGISTRATION
At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to Polaris
within ten days. Upon receipt of this registration, Polaris will record the registration for warranty. No verification
of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty
entitlement. If you have not signed the original registration and received the “customer copy”, please contact your
dealer immediately. NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REGIS-
TERED WITH POLARIS.
Initial dealer preparation and set-up of your ATV is very important in ensuring trouble-free operation. Purchasing
a machine in the crate or without proper dealer set-up will void your warranty coverage.
187
Warranty
WARRANTY COVERAGE AND EXCLUSIONS:
LIMITATIONS OF WARRANTIES AND REMEDIES
The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship.
This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This war-
ranty also does not cover any ATV that has been altered structurally, modified, neglected, improperly maintained,
used for racing, or used for purposes other than for which it was manufactured, or for any damages which occur
during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, this war-
ranty does not cover physical damage to paint or finish, stress cracks, tearing or puncturing of upholstery mate-
rial, corrosion, or defects in parts, components or the ATV due to fire, explosions or any other cause beyond
Polaris' control.
This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with
the ATV. The exclusive remedy for breach of this warranty shall be, at Polaris' exclusive option, repair or replace-
ment of any defective materials, or components or products. THE REMEDIES SET FORTH IN THIS WAR-
RANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS
WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSE-
QUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS
OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHER-
WISE. Some states do not permit the exclusion or limitation of incidental or consequential damages or implied
warranties, so the above limitations or exclusions may not apply to you if inconsistent with controlling state law.
188
Warranty
WARRANTY COVERAGE AND EXCLUSIONS:
LIMITATIONS OF WARRANTIES AND REMEDIES
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO
THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS
WARRANTIES 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.
189
Warranty
HOW TO OBTAIN WARRANTY SERVICE
If your ATV requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris ATVs.
When requesting warranty service you must present your copy of the Warranty Registration form to the dealer.
(THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). Polaris
suggests that you use your original selling dealer; however, you may use any Polaris Servicing Dealer to perform
warranty service.
Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance
they will contact the appropriate personnel at Polaris.
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
If any of the above terms are void because of state or federal law, all other warranty terms will remain in effect.
Engine Oil
1. Mixing oil brands or using non-recommended oil may cause engine damage. We recommend the use of Polaris
engine oil.
2. Damage resulting from the use of non-recommended lubricants may not be covered by warranty.
Spark Arrestor
Polaris warrants that the spark arrestor in this vehicle will meet the efficiency requirements of 43 CFR 8340.1(c)
for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance
with Polaris recommendations.
190
Warranty
EXPORTED VEHICLES
EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BUL-
LETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING
DEALER'S AUTHORIZED LOCATION.
This policy does not apply to vehicles that have received authorization for export from Polaris Industries. Dealers
may not give authorization for export. You should consult an authorized dealer to determine this vehicle's war-
ranty or service bulletin coverage if you have any questions.
This policy does not apply to vehicles registered to government officials or military personnel on assignment out-
side the country of the selling dealer's authorized location.
This policy does not apply to Safety Recalls.
191
Warranty
EXPORTED VEHICLES
How to Get Service
In the country where your vehicle was purchased:
Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you move or are traveling
within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested
from any authorized Polaris dealer who sells the same line as your vehicle.
Outside the country where your vehicle was purchased:
If you are traveling temporarily outside the country where your vehicle was purchased, you should take your
vehicle to an authorized Polaris dealer. You must show the dealer photo identification from the country of the sell-
ing dealer's authorized location as proof of residence. Upon residence verification, the servicing dealer will be
authorized to perform the warranty repair.
If You Move:
If you move to another country, be sure to contact Polaris Customer Assistance and the customs department of the
destination country before you move. Vehicles importation rules vary considerably from country to country. You
may be required to present documentation of your move to Polaris Industries in order to continue your warranty
coverage. You may also be required to obtain documentation from Polaris Industries in order to register your
vehicle in your new country.
192
Warranty
EXPORTED VEHICLES
How to Get Service
If Purchased From A Private Party:
If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally
purchased, all warranty coverage will be denied.
Notice
If your vehicle is registered outside of the country where it was purchased, and you have not followed the proce-
dure set out above, your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind.
(Vehicles registered to Government officials or military personnel on assignment outside of the country where the
vehicle was purchased will continue to be covered by the basic warranty.)
For questions call Polaris Customer Assistance:
United States: 1-888-704-5290
Canada: 1-204-925-7100
193
Warranty
U.S.A. EPA Emissions Limited Warranty
This All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited warranty is in addition to
the Polaris standard limited warranty for this vehicle.
Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at the time of initial sale with
the requirements of 40 CFR 1051 and, (2) free from defects in materials and workmanship that may keep it from
meeting these requirements.
The emissions warranty period for this vehicle begins on the date the vehicle is delivered to the original retail pur-
chaser and ends 30 months (2.5 years) after that date, after 5000 km (3100 miles), or after 500 hours of operation,
whichever comes first.
This emission-related warranty covers components whose failure would increase an engine's emissions, including
electronic controls, fuel injection, exhaust-gas recirculation, aftertreatment, or any other system utilized in this
vehicle to control emissions. Replacing or repairing other components not covered by this emissions warranty or
the standard warranty is the responsibility of the owner; including the parts, labor and other costs associated with
recommended maintenance.
194
Warranty
U.S.A. EPA Emissions Limited Warranty
The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of Polaris, repair or
replacement of any defective materials, components or products. THE REMEDIES SET FORTH IN THIS LIM-
ITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS
WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSE-
QUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION,WHETHER ARISING OUT OF EXPRESS
OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR OTHER-
WISE.
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO
THE WARRANTY PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS WARRANTIES
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 if it is inconsistent with the controlling state law.
This limited warranty excludes failures not caused by a defect in material or workmanship. This limited warranty
does not cover damage due to accidents, abuse or improper handling, maintenance or use. This limited warranty
also does not cover any engine that has been structurally altered, or any engine that has been used in racing com-
petition. This limited warranty also does not cover physical damage, corrosion or defects caused by fire, explo-
sions or other similar causes beyond the control of Polaris.
If you have any questions regarding your warranty rights and responsibilities, you should contact the Polaris War-
ranty Department at 1-888-704-5290.
195
Maintenance Log
Present this section of your manual to your dealer each time your vehicle is serviced. This will provide you and
future owners with an accurate log of maintenance and services performed.
DATE SERVICE
INTERVAL
(HOURS)
TECHNICIAN SERVICE PERFORMED / COMMENTS
3 Hours
(Break-in)
15
30
45
196
Maintenance Log
DATE SERVICE
INTERVAL
(HOURS)
TECHNICIAN SERVICE PERFORMED / COMMENTS
60
90
197
Maintenance Log
DATE SERVICE
INTERVAL
(HOURS)
TECHNICIAN SERVICE PERFORMED / COMMENTS
198
Maintenance Log
DATE SERVICE
INTERVAL
(HOURS)
TECHNICIAN SERVICE PERFORMED / COMMENTS
199
Index
A
Age Restrictions . . . . . . . . . . . . . . 15
Air Filter Systems . . . . . . . . . . . . 112
B
Battery
Charging. . . . . . . . . . . . 132-134
Installation . . . . . . . . . . . . . 131
Maintenance. . . . . . . . . . . . 129
Removal . . . . . . . . . . . . . . . 130
Storage . . . . . . . . . . . . 130, 162
Bleeding the Cooling System . . . 111
Boots . . . . . . . . . . . . . . . . . . . . . . . 14
Brake Fluid . . . . . . . . . . . . . . . . 48-49
Brake Maintenance . . . . . . . . 142-143
Brakes
Foot Brake . . . . . . . . . . . . . . 46
Hand Brake . . . . . . . . . . . . . 47
Parking Brake . . . . . . . . . 50-51
Break-in Period . . . . . . . . . . . . . 58-59
C
Cab Removal, Front . . . . . . . . . . . 120
Cab Removal, Rear . . . . . . . . . . . 121
Camber and Caster . . . . . . . . . . . . 151
Carburetor . . . . . . . . . . . . . . 113-114
Carburetor Draining . . . . . . . . . . . 114
Carburetor Jetting. . . . . . . . . . . . . 115
Chain Tension Adjustment. . 148-149
Chain Tension Inspection. . . 146-147
Cleaning . . . . . . . . . . . . . . . . 158-160
Clothing . . . . . . . . . . . . . . . . . . . . . 14
Clutch Fluid . . . . . . . . . . . . . . . . . . 43
Clutch Lever. . . . . . . . . . . . . . . . . . 42
Clutch System Bleeding. . . . 138-139
Compression Damping. . . . . . . . . 153
Compression Damping, Rear . . . . 157
Consumer Product Safety. . . . . . . . 11
Coolant Level, Radiator . . . . . . . . 110
Coolant Level, Recovery Bottle. . 109
Cooling System . . . . . . . . . . 108-111
Cooling System Bleeding. . . . . . . 111
D
Deceleration . . . . . . . . . . . . . . . . . 55
Driving Downhill . . . . . . . . . . . . . 78
Driving in Reverse . . . . . . . . . . 82-83
Driving on a Sidehill . . . . . . . . . . . 74
Driving on Slippery Surfaces . . 70-71
Driving Over Obstacles. . . . . . . . . 84
Driving Procedures . . . . . . . . . . . . 68
Driving Through Water. . . . . . . 80-81
Driving Uphill . . . . . . . . . . . . . . 72-73
E
Electronic Throttle Control . . . . . . 45
Emission Control Systems . . . . 85-86
Engine Idle Speed . . . . . . . . . . . . 113
Equipment Modifications . . . . . . . 12
Etiquette, Trail Riding. . . . . . . . . . 65
Exhaust, Exposure to. . . . . . . . . . . 17
Eye Protection . . . . . . . . . . . . . . . . 14
200
Index
F
Fluid
Brake . . . . . . . . . . . . . . . . 48-49
Clutch . . . . . . . . . . . . . . . . . . 43
Foot Brake . . . . . . . . . . . . . . . . . . . 46
Foot Brake Fluid Level . . . . . . . . . 49
Fuel Filter . . . . . . . . . . . . . . . . . . . . 56
Fuel Safety . . . . . . . . . . . . . . . . . . . 17
Fuel Stabilizer . . . . . . . . . . . . . . . 164
Fuel Tank . . . . . . . . . . . . . . . . . . . . 56
Fuel Valve . . . . . . . . . . . . . . . . . . . 57
G
Gasoline Handling . . . . . . . . . . . . . 17
Gloves. . . . . . . . . . . . . . . . . . . . . . . 14
H
Hand Brake. . . . . . . . . . . . . . . . . . . 47
Hand Brake Fluid Level . . . . . . . . . 49
Handlebar Adjustment . . . . . . . . . 150
Headlight Adjustment . . . . . 116-117
Headlight Assembly . . . . . . . . . . . 119
Headlights. . . . . . . . . . . . . . . . . . . . 41
Helmet . . . . . . . . . . . . . . . . . . . . . . 13
I
Idle Speed . . . . . . . . . . . . . . . . . . 113
Indicator Lights . . . . . . . . . . . . . . . 40
Instruction, Operating . . . . . . . . . . 16
J
Jetting . . . . . . . . . . . . . . . . . . . . . 115
Jetting Specifications
Outlaw 450 MXR . . . . . . . . 169
Outlaw 525 S . . . . . . . . . . . 171
K
Key Switch . . . . . . . . . . . . . . . . . . 39
K-Turn . . . . . . . . . . . . . . . . . . . . . . 75
L
Lights . . . . . . . . . . . . 40-41, 116-119
Headlight Adjustment. 116-117
Headlight Assembly . . . . . . 119
Headlights. . . . . . . . . . . . . . . 41
Indicator Lights . . . . . . . . . . 40
M
Main Key Switch . . . . . . . . . . . . . . 39
Maintenance Chart . . . . . . . . . . 87-97
Making Turns . . . . . . . . . . . . . . . . . 69
Manual Shift . . . . . . . . . . . . . . . 52-55
Master Cylinder . . . . . . . . . . . . 48-49
Modifications . . . . . . . . . . . . . . . . . 12
O
Oil Change, Engine. . . . . . . . 100-107
Oil Level, Engine . . . . . . . . . . . . . . 99
Oil Recommendations . . . . . . . . . . 98
Operator Restrictions . . . . . . . . . . . 15
P
Parking Brake . . . . . . . . . . . . . . 50-51
Parking on a Hill or Incline . . . . . . 79
Passenger Warning . . . . . . . . . . . . . 37
Periodic Maintenance Chart . . . 87-97
Polaris Products . . . . . . . . . . . . . . 172
Polishing . . . . . . . . . . . . . . . . . . . . 161
Pre-Ride Inspection . . . . . . . . . 60-61
201
Index
R
Rebound Damping, Rear. . . . . . . 156
Restrictions, Age. . . . . . . . . . . . . . 15
Reverse Lock-Out Switch . . . . . . . 54
Riding Area. . . . . . . . . . . . . . . . . . 64
Riding Gear. . . . . . . . . . . . . . . . 13-14
S
Safe Operation Practices . . . . . . 62-63
Safety Labels and Locations . 34-37
Age 16 Warning . . . . . . . . . . 36
Discretionary Warning. . . . . 36
General Warning . . . . . . . . . 35
No Passenger Warning. . . . . 37
Sport ATV Warning. . . . . . . 36
Tire Pressure/Load Warning 37
Safety Training . . . . . . . . . . . . . 10-11
Safety Warnings . . . . . . . . . . . 15-33
Age Restrictions. . . . . . . . . . 15
Carrying a Passenger . . . . . . 19
Crossing Hillsides . . . . . . . . 25
S
Safety Warnings . . . . . . . . . . . 15-33
Damaged ATV . . . . . . . . . . . 32
Deep Water . . . . . . . . . . . . . . 30
Descending Hills Improperly 24
Excessive Speed . . . . . . . . . . 21
Exposure to Exhaust . . . . . . . 17
Failure to Inspect . . . . . . . . . 18
Frozen Bodies of Water . . . . 32
Handling Gasoline. . . . . . . . . 17
Hot Exhaust Systems . . . . . . 33
Improper Cargo Loading. . . . 31
Improper Hill Climbing . . . . 23
Improper Tire Maintenance . 28
Improper Modifications . . . . 29
Instruction . . . . . . . . . . . . . . . 16
Jumps and Stunts. . . . . . . . . . 22
Obstacles . . . . . . . . . . . . . . . . 29
Pavement . . . . . . . . . . . . . . . . 20
Physical Control of the ATV 21
Physical Skills . . . . . . . . . . . . 32
S
Safety Warnings . . . . . . . . . . . 15-33
Poor Visibility . . . . . . . . . . . 31
Protective Apparel . . . . . . . . 18
Public Roads. . . . . . . . . . . . . 20
Reverse. . . . . . . . . . . . . . . . . 28
Skidding or Sliding . . . . . . . 29
Slippery Terrain . . . . . . . . . . 27
Stalling Climbing a Hill . . . . 26
Steep Hills . . . . . . . . . . . . . . 23
Turning Improperly . . . . . . . 22
Unauthorized Use. . . . . . . . . 33
Unfamiliar Terrain . . . . . . . . 28
Using Alcohol or Drugs . . . . 19
Safety Words and Symbols . . . . . . . 6
Severe Use. . . . . . . . . . . . . . . . . . . 88
Shift Pedal . . . . . . . . . . . . . . . . . . . 52
Shifting Gears . . . . . . . . . . . . . . . . 53
Side Panel Removal . . . . . . . . . . 120
Sidehilling . . . . . . . . . . . . . . . . . . . 74
Signal words . . . . . . . . . . . . . . . . . . 6
202
Index
S
Spark Arrestor Clean-Out. . . 124-125
Spark Plugs. . . . . . . . . . . . . . 122-123
Spring Preload . . . . . . . . . . . . . . . 153
Spring Preload, Front . . . . . . . . . . 154
Spring Preload, Rear . . . . . . . . . . 155
Starting the Engine . . . . . . . . . . 66, 67
Steering Inspection . . . . . . . . . . . . 151
Storage . . . . . . . . . . . . . . . . . 162-165
Suspension
Front . . . . . . . . . . . . . . 153-154
Rear . . . . . . . . . . . . . . . 155-157
Suspension Settings . . . . . . . . . . . 152
Switches
Engine Stop Switch . . . . . . . . 39
Main Key Switch. . . . . . . . . . 39
Reverse Lock-Out Switch . . . 54
Start Button . . . . . . . . . . . . . . 39
T
Throttle Cable Freeplay. . . . . . . . 141
Throttle Lever . . . . . . . . . . . . . 44-45
Throttle Lever Freeplay. . . . . . . . 140
Tires
Installation . . . . . . . . . . . . . 137
Removal . . . . . . . . . . . . . . . 136
Tread Depth . . . . . . . . . . . . 135
Wheel Hub Tightening . . . . 136
Toe Alignment. . . . . . . . . . . 144-145
Trail Etiquette . . . . . . . . . . . . . . . . 65
Transporting the ATV . . . . . 166-167
Tread Lightly . . . . . . . . . . . . . . . . . 64
Turning Around on a Hill . . . . 75-77
V
Vehicle Identification Numbers . . 8-9
Vehicle Immersion . . . . . . . . 126-128
W
Warranty, Emissions. . . . . . . 193-194
Washing the Vehicle. . . . . . . 158-160
Wheel Hub Tightening . . . . . . . . . 136
Wheel Installation. . . . . . . . . . . . . 137
Wheel Removal . . . . . . . . . . . . . . 136
