WARNING Improper vehicle 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. Operate on public roads. A collision can occur with another vehicle. Operate at speeds too fast for your skills or the conditions. Use ALCOHOL or DRUGS before or while operating this vehicle. Carry Passengers.
WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. 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.
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All information in this manual is based on the latest product data and specifications available at the time of printing. Polaris Industries Inc. reserves the right to make product changes and improvements that may affect illustrations or explanations. No part of this manual shall be reproduced or used without the written permission of Polaris Industries Inc. Copyright 2002 Polaris Industries Inc. All Rights Reserved 2 Printed in the U.S.A.
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.
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TABLE OF CONTENTS WELCOME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 VEHICLE IDENTIFICATION NUMBERS . . . . . . . . . . . . . . . 6 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 FEATURES AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . 37 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE IDENTIFICATION NUMBERS The vehicle frame vehicle identification number (VIN)(1) and engine serial number (2) are important for model identification when registering your vehicle, when obtaining insurance, and when ordering replacement parts. If your vehicle is stolen, these numbers are essential to the recovery and identification of your vehicle. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys.
SAFETY Operator Safety WARNING Failure to follow the warnings contained in this manual can result in severe injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.
SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your ATV. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your ATV or in this manual, alerts you to the potential for personal injury. WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death.
SAFETY Operator Safety WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner’s manual. S Read this manual and all labels carefully, and follow the operating procedures described. S Never operate an ATV without proper instruction. Take a training course. Beginners should receive training from a certified instructor.
SAFETY Operator Safety S Always have the ATV inspected by an authorized Polaris dealer if it’s been involved in an accident. S Never operate on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills. S Always follow proper procedures for climbing hills. Check the terrain carefully before ascend a hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes.
Operator Safety SAFETY S Wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them lightly several times to allow friction to dry out the pads. S Always check for obstacles or people behind the ATV before operating in reverse. When it’s safe to proceed in reverse, move slowly and avoid turning at sharp angles. S Always use the size and type of tires specified for your ATV, and always maintain proper tire pressure.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain. HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Polaris.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Carrying a passenger on an ATV. WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator’s ability to balance and control the ATV, which could cause an accident and injury to the operator and/or passenger. HOW TO AVOID THE HAZARD Never carry a passenger. The purpose of the long seat is to allow the operator to shift position as needed during operation. It is not intended for carrying passengers.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating an ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways. WHAT CAN HAPPEN ATV tires are designed for off-road use. Operating on paved surfaces may seriously affect the handling and control of the ATV and could result in loss of control, accident, and/or injury. HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement. If it’s unavoidable, travel slowly and avoid sudden turns or stops.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN The ATV could collide with another vehicle. HOW TO AVOID THE HAZARD Never operate the ATV on any public street, road or highway, including dirt and gravel roads. In many states it’s illegal to operate ATVs on public streets, roads and highways.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident. Operating without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident. HOW TO AVOID THE HAZARD Always wear an approved helmet that fits properly.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating the ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Consumption of alcohol and/or drugs could seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected. Consuming alcohol and/or drugs before or while operating an ATV could result in an accident causing severe injury or death. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while operating an ATV.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Attempting stunts increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt wheelies, jumps, or other stunts. Avoid exhibition driving.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV before each use to make sure it’s in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the owner’s manual.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain. WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn. HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain. Always be alert to changing terrain conditions.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Operating on excessively rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you’ve learned and practiced the skills necessary to control the ATV on such terrain.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner’s manual. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speed. WARNING POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle may overturn.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner’s manual. Always check the terrain carefully before ascending any hill. Never operate the ATV on hills steeper than 25_. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Traveling downhill improperly. WHAT CAN HAPPEN Improperly descending a hill could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner’s manual. NOTE: A special technique is required when braking while traveling downhill. See page 65. Always check the terrain carefully before you descending a hill. Shift your weight backward. Never travel down a hill at high speed.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Improperly crossing hills and turning on hills. WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of control or overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you’ve mastered the turning technique (on level ground) as described in the owner’s manual. See page 66. Use extra caution when turning on any hill. Avoid crossing the side of a steep hill.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN The vehicle could overturn. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. If all forward speed is lost: Keep your weight uphill. Apply the front brake (or the single lever brake, gradually). When fully stopped, apply the rear brake as well, then lock the parking brake. If the ATV begins rolling backwards: Keep weight uphill.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees when possible. If unavoidable, use extreme caution and always follow proper procedures as outlined in the owner’s manual. WARNING POTENTIAL HAZARD Skidding or sliding.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating the ATV through deep or fast-flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast-flowing water.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires, or operation of the ATV with improper or uneven tire pressure, could cause loss of control or accident. HOW TO AVOID THE HAZARD Always use the size and type of tires specified in the owner’s manual for the ATV. Always maintain proper tire pressure. WARNING POTENTIAL HAZARD Operating the ATV with improper modifications.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Overloading the ATV or carrying/towing cargo improperly. WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling, which could lead to loss of control or an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow a greater distance for braking.
SAFETY Operator Safety WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use. WARNING After any overturn or accident, have a qualified service dealer inspect the entire vehicle for possible damage, including (but not limited to) brakes, throttle and steering systems. WARNING Safe operation of this rider-active vehicle requires good judgement and physical skills.
SAFETY Safety Decals and Locations Warning decals have been placed on the ATV for your protection. Read and follow the instructions on each decal carefully. If a decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal.
SAFETY Safety Decals and Locations WARNING DNever operate this vehicle on HILLS steeper than 25 degrees 25°. To prevent flipover on hilly terrain, when going up or down, use throttle and brakes gradually. DREVERSE operation can be dangerous, even at low speeds. Steering becomes difficult. To prevent flipover, avoid sudden braking or sharp turns. DUse OVERRIDE for reverse speed limiter with caution. To prevent loss of control, never activate override button with open throttle.
SAFETY Safety Decals and Locations WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH. TIRE PRESSURE IN PSI (KPa): FRONT 5 (34,5) REAR 5 (34,5) MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING MACHINE, DRIVER AND CARGO IS 1300 LBS. (590 kg) MAXIMUM CARGO CAPACITY 350 LBS. (158 kg) Reduce speed and allow greater distance for braking when carrying cargo.
SAFETY Safety Decals and Locations WARNING Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed. Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM which can result in serious injury or death. 7078689 NO STEP WARNING Pushing reverse override button may cause sudden increases in power and traction if too much throttle is applied.
SAFETY Safe Riding Gear Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injury. Select an approved helmet that meets or exceeds your state’s safety standards and bears either the Department of Transportation (DOT) label, the American National Standards Institute label (ANSI z90.
FEATURES AND CONTROLS Electrical Switches 3 1 2 WARNING While operating in reverse, activating the override switch with the throttle open can cause loss of control, resulting in severe injury or death. Do not activate the override switch while the throttle is open. Speedo Mode/Override Switch (1) (Reverse Speed Limiter) - This switch, if pressed while in any gear but reverse, will change the display mode of the speedometer (if equipped).
FEATURES AND CONTROLS Electrical Switches Engine Stop Switch (3) - The engine will OFF RUN OFF not start or run when the switch is in the OFF position. Its purpose is to provide the operator with a quick means of engine shutdown in case of an emergency. To stop 3 the engine, slide the stop switch either right or left to the OFF position. NOTE: Turning off the engine stop switch will shut off all electrical power to the vehicle, with the exception of the cooling fan on some models.
FEATURES AND CONTROLS WARNING Do not start or operate an ATV with sticking or improperly operating throttle controls, which could cause an accident and lead to severe injury or death. Always contact your dealer for service repairs if throttle problems arise. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation. Always check the lever for free movement and return before starting the engine.
FEATURES AND CONTROLS Brake Lever The front and rear brakes are applied by squeezing the brake lever (1) toward the handlebar. The front and rear brakes are hydraulically activated disc type brakes that are activated by only one lever. 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 test brake lever travel and master cylinder fluid level before riding.
Parking Brake FEATURES AND CONTROLS WARNING Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating. Locking the Parking Brake 1 1. Squeeze and release the brake 2 lever (1) two or three times, then squeeze and hold at full stroke. 2. Push the park brake lock (2) forward to engage the brake. Release the brake lever. 3.
FEATURES AND CONTROLS Auxiliary Brake WARNING Aggressively applying the rear brake when backing down a hill may cause rear tipover, which could result in serious injury or death. If the rear brake is applied aggressively while moving forward, the rear wheels may skid and slide sideways, causing loss of control and serious injury or death. Always use caution when applying the auxiliary foot brake. Do not apply the auxiliary foot brake aggressively.
Choke FEATURES AND CONTROLS The choke assists in starting a cold engine. Refer to the engine starting procedure on page 55 for correct choke and throttle settings during starting. Fuel Valve The fuel valve (1) is located on the left side panel. It has three positions: OFF: For vehicle storage and when transporting. ON: For normal operation. RES: For reserve supply if main supply is exhausted. 1 NOTE: There’s about a 7 to 10 mile (11.2 to 16 km) range on reserve gas.
FEATURES AND CONTROLS Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a S S S S S S well ventilated area. Never fill a gas container while it’s in the cargo box. Static electricity between the box and container could cause a spark.
FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector (1) is located on the right side of the vehicle. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park 1 H L N R P To shift into HIGH or PARK, you must first apply the auxiliary brake to activate the high/park lock-out mechanism. When shifting out of HIGH or PARK, it’s not necessary to apply the brake.
FEATURES AND CONTROLS Recoil Starter 1 If the battery is weak and cannot start the engine, use of the recoil starter (1) will allow vehicle operation until repairs can be made. The recoil starter is located on the right side of the machine. Polaris 4-cycle engines are equipped with automatic decompressors. This makes recoil starting possible by allowing compression to “leak” at cranking speeds. The decompressor senses when the engine is spinning fast enough to start and restores compression for starting. 1.
FEATURES AND CONTROLS All Wheel Drive (AWD) System Polaris 4 wheel drive ATVs are equipped with a unique, Polaris exclusive, Demand 4 Drive (AWD) system activated by a switch (1) on 1 the right handlebar. When the switch is on 2x4 (center position), the ATV is in two wheel drive at all times and the differential is locked. When the switch is on AWD (left position), the ATV is in Demand 4 Drive and the differential is locked.
FEATURES AND CONTROLS Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV’s speed to approximately 7-9 mph. Refer to page 37 for additional information. 3 2 1 1. Rider Information Center 2.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. All segments will light up for 2.5 seconds at start-up. NOTE: If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electrical system. If this occurs, take the ATV to your Polaris dealer for proper diagnosis. 1.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center has 4 standard modes: Mode 1 - Odometer Mode 2 - Tripmeter Mode 3 - Total Service Hours Mode 4 - Tachometer The reverse override button on the left handlebar is also the mode button. NOTE: If using the mode button to program the rider information center, or to toggle through the options, the machine cannot be in reverse. Mode 1 - Odometer The odometer records the miles traveled by the ATV.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The diagnostic mode is for informational purposes only. Please return your ATV to your dealer for all major repairs. As long as the gauge is in the diagnostic mode, the wrench icon will remain lit. To leave the diagnostic mode, either shift the machine out of neutral or turn the key switch off and on. NOTE: Any movement of the tires will also take the machine out of the diagnostic mode. To enter the diagnostics mode: 1.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Screen 5: Programmable service interval The purpose of the programmable service interval is to provide the consumer and dealer with a convenient reminder for routine maintenance. When your vehicle leaves the factory, this feature is set at 50 hours. You must enable the programmable service interval before it can be used.
OPERATION Break-In Period The break-in period for your new Polaris ATV is defined as the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the procedures for a proper break-in. Careful treatment of a new engine will result in more efficient performance and longer life for the engine. Perform the following procedures carefully.
OPERATION Pre-Ride Inspection WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it’s in proper operating condition. Use the following checklist to verify that your vehicle is in proper working condition before each use. Item/Inspection Procedure 1. Tires - Check condition and pressures. 2. Fuel and oil tanks - Fill both tanks to their proper levels. 3.
Starting the Engine OPERATION Starting a Cold Engine WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. CAUTION Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating the vehicle. 1. Place the transmission in park and lock the parking brake. 2. Turn the fuel tank valve on. 3. Sit on the vehicle. 4.
OPERATION Starting the Engine Starting a Warm Engine Warm engines do not normally require the use of the choke. Using the choke can cause the spark plug to become wet fouled. 1. Position the vehicle on a level surface with the transmission in park. 2. Lock the parking brake, turn the fuel tank valve to ON, sit on the vehicle, and turn the engine stop switch to RUN. 3.
OPERATION Hauling Cargo WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo: S Never exceed the stated load capacity for this vehicle. S Reduce speed and allow a greater distance for braking. S When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions.
OPERATION Hauling Cargo Load Distribution Your ATV has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warnings listed on the warning labels, and never exceed the specified weights. Cargo weight should be mounted as low as possible. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions. 1. Always load the cargo box with the load as far forward as possible. 2.
OPERATION Hauling Cargo Dumping Cargo 1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Place the transmission in park and set the parking brake. 3. Dismount the vehicle. 4. Lower the tailgate. WARNING If cargo weight is placed toward the rear of the cargo box, the load may dump unexpectedly and cause serious injury. When loading cargo, always position the weight as far forward and as low as possible. 5. 6. 7. 8.
OPERATION Driving Safely Driving Procedures 1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. Start the engine and allow it to warm up, then shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4. Release the parking brake. 5. Slowly depress the throttle with your right thumb and begin driving. Vehicle speed is controlled by the amount of throttle opening. 6. Drive slowly.
OPERATION Driving Safely Making Turns Your Polaris ATV is equipped with a rear differential that functions as a solid rear axle, driving both rear wheels equally when the ATP is in either 2x4 or 4x4 mode. This means that the wheel on the outside of a turn must travel a greater distance than the inside wheel, causing the inside tire to slip traction slightly.
OPERATION Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Slow down when entering slippery areas. 2. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns which can cause skids. 3. Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward. 4.
OPERATION Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid steep hills (25_ maximum). 3. Keep both feet on the footrests. 4. Transfer your weight forward. 5. Proceed at a steady rate of speed and throttle opening. 6. Remain alert and be 25_ Maximum prepared to take emergency action. This may include quick dismounting of the vehicle. If all forward speed is lost: Keep your weight uphill.
OPERATION Driving Safely Sidehilling WARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner’s manual. Sidehilling can be a dangerous type of driving and should be avoided if at all possible. If you do enter into a situation where sidehilling is necessary, follow these precautions: 1. Slow down. 2.
OPERATION Driving Safely Driving Downhill Whenever descending a hill, follow these precautions: 1. Proceed directly downhill. 2. Transfer your weight to the rear of the vehicle. 3. Slow down. 4. Apply the brakes slightly to aid in slowing. Familiarize yourself with operation of the auxiliary rear brake pedal for additional braking in the event of normal service brake loss. WARNING Excessive speed can cause loss of control and lead to serious injury or death. Always operate slowly when traveling downhill.
OPERATION Driving Safely Turning Around on a Hill WARNING Improper hill climbing procedures could cause loss of control or overturn and result in serious injury or death. Avoid climbing steep hills (25_ maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner’s manual. If the vehicle stalls while climbing a hill, never back it down the hill! One maneuver that can be used when it’s necessary to turn around while climbing a hill is the K-turn: 1.
OPERATION Driving Safely Driving Through Water 1 Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests (1). Follow these procedures when operating through water: 1. Determine water depths and current before crossing. 2. Choose a crossing where both banks have gradual inclines. 3. Proceed slowly, avoiding rocks and obstacles if possible. 4. After crossing, dry the brakes by applying light pressure to the lever until braking action is normal.
OPERATION Driving Safely Driving Through Water After running the vehicle in water, it’s critical to have it serviced as outlined in the maintenance chart. See page 75. The following areas need special attention: engine oil, transmission oil, front and rear gearcases and all grease fittings. NOTE: If water has been ingested into the PVT, follow the procedure on page 73 for drying out the PVT.
OPERATION Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches. WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. Not all obstacles are immediately visible. Travel with caution in unfamiliar terrain.
OPERATION Driving Safely Driving in Reverse Follow these precautions when operating in reverse: 1. Always avoid backing downhill. 2. Back slowly. 3. When in reverse, apply the brakes lightly for stopping. 4. Avoid turning at sharp angles in reverse. 5. Never open the throttle suddenly while backing. WARNING Failure to use caution when operating in reverse can result in serious injury or death. Before shifting into reverse, always check for obstacles or people behind the vehicle.
Driving Safely OPERATION Parking on an Incline Avoid parking on an incline if possible. If it’s unavoidable, follow these precautions: 1. Turn the engine off. 1. Place the transmission in park. 2. Set the parking brake. 3. Always block the rear wheels on the downhill side as shown in illustration. 4. Shut off the fuel supply.
OPERATION PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of “pinch” applied to the drive belt. Similarly, if the engine speed decreases, the amount of centrifugal force decreases, reducing the amount of belt “pinch.
OPERATION PVT System WARNING Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components. The PVT system rotates at high speeds, creating large amounts of force on clutch components.
EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with state and local noise level requirements. Spark Arrestor Your Polaris vehicle has a spark arrestor that was tested and approved in accordance with the USDA Forest Service Standard 5100-1C. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands.
MAINTENANCE AND LUBRICATION Accessories Polaris has a wide range of accessories available for your ATV. Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights. Accessory outlets are available for all models. See your Polaris dealer for more information about accessories. Periodic Maintenance Schedule Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition.
MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Hours of operation are based on a 10 mph average. If service is due at 20 hours, the equivalent odometer reading would be 200 miles. Perform all services at whichever reading is reached first. WARNING Improperly performing the procedures marked with a J could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services.
MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Item Hours/ Miles Taillight/brakelight Pre-Ride Pre-Ride Check operation daily; apply Polaris dielectric grease to socket when replaced " Air filter, Weekly Weekly Inspect; replace as needed " Transmission oil 20 hrs Monthly Inspect monthly; change annually 20 hrs Monthly Check terminals; clean.
MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule WARNING Improperly performing the procedures marked with a J could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. Item Hours/ Miles Frequency Remarks Carburetor float bowl 50 hrs. 6 months Drain bowl periodically and prior to storage J Throttle Cable/ETC 50 hrs. 6 months Inspect; adjust; lubricate; replace if necessary L Choke (enricher) 50 hrs.
MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Item Hours/ Miles Frequency Remarks 100 hrs. 12 months Check for leaks at tank cap, lines, fuel valve, filter, pump and carburetor; replace lines every two years 100 hrs. 12 months Replace annually Radiator (500) 100 hrs. 12 months Inspect; clean external surface Cooling system hoses (500) 100 hrs. 12 months Inspect " Front gearcase 100 hrs. 12 months Change fluid annually J Clutches 100 hrs.
MAINTENANCE AND LUBRICATION Lubrication Recommendations NOTE: Hours are based on 10 mph average. If service is due at 20 hours, the equivalent odometer reading would be 200 miles. Perform all services at whichever reading is reached first. Lubrication Chart Key " More often under severe use, such as wet or dusty conditions F No.
MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance. Maintenance Interval Performed Servicing Servicing Date Dealer or Person Remarks 10 hrs. 20 hrs. 50 hrs. 100 hrs.
MAINTENANCE AND LUBRICATION Lubrication Recommendations Premium 4 Synthetic Oil Polaris Premium 4 All Season Synthetic engine oil has been specially formulated for use in Polaris 4-cycle engines. It’s a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection. NOTE: See page 121 for the part numbers of Polaris products. Premium 4 possesses unsurpassed film strength over the widest possible temperature range.
MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change - ATP 500 4x4 The recommended oil change interval is 100 hours, 1000 miles, or every six months, whichever comes first. Suggested break-in oil change is at 20 hours, 200 miles, or one month, whichever comes first. Severe use requires more frequent service. Severe use includes continuous duty in dusty or wet conditions and cold weather operation. Severe use cold weather operation is all operation below 10° F.
MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change - ATP 500 4x4 4. Place a drain pan beneath the oil tank and remove the drain plug (1). Allow the oil to drain completely. 5. Install a new sealing washer (2) on the oil drain plug. NOTE: The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs, nicks or scratches. 6. Reinstall the drain plug and torque to 14-17 ft. lbs. (1.93-2.35 kg/m) 7.
MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change - ATP 500 4x4 8. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter 2 (1) counterclockwise and remove. 9. Lubricate the gasket on the 1 new filter with a film of new engine oil. Check to make sure the gasket is in good condition. Also make sure the gasket from the old filter is not still on the engine. 10.
MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change - ATP 330 4x4 CAUTION 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. Always replace the oil and filter within a few hours of draining the oil. Do not allow the vehicle to be without oil overnight. 1. Obtain the correct oil filter and an adequate supply of oil so the oil and filter change can be completed without interruption. 2.
MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change - ATP 330 4x4 8. Reinstall the drain plug and torque to 14 ft. lbs. (19 Nm). 9. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter counterclockwise to remove. 10. Using a clean, dry cloth, clean the filter sealing surface on the crankcase. 11. Lubricate the gasket on the new filter with a film of engine oil. Check to make sure the gasket is in good condition. 12.
MAINTENANCE AND LUBRICATION Lubrication Recommendations Transmission Oil Check The transmission lubricant level should be checked every six months or 1000 miles (1600 km), whichever comes first. Transmission oil should be changed annually. 1 1. Position the ATV on a level surface, remove the fill plug (1), and check the oil level. NOTE: The transmission fill plug is located on the right side of the machine, behind the footwell. 2.
MAINTENANCE AND LUBRICATION Lubrication Recommendations Front Gearcase Oil Check The front gearcase oil level should be checked every six months or 1000 miles (1600 km), whichever comes first. The oil should be changed annually. We recommend the use of Polaris Premium Hub Drive Fluid. See page 121 for the part numbers of Polaris products. With the ATV on a level surface, remove the fill plug and check the oil level. The level should be maintained 3/4” below the fill plug opening.
MAINTENANCE AND LUBRICATION Lubrication Recommendations Rear Gearcase Oil Check With the ATV on a level surface, remove the fill plug and view the oil level through the fill hole (1). Lubricant should be kept even with the bottom of the fill hole. Use Polaris Premium Synthetic Gearcase Lube (or GL5 80-90 weight gear lube). NOTE: See page 121 for the part numbers of Polaris products. 1 Rear Gearcase Oil Change 1. Remove the drain plug (2). Catch 1 and discard used oil properly. 2.
MAINTENANCE AND LUBRICATION Engine Cooling System Oil Cooler (ATP 330) The oil cooling system requires little maintenance other than to make sure the cooler is kept free of mud and debris. Change the engine oil as recommended in the maintenance schedule. Coolant Level (ATP 500) The recovery bottle (1) is located on the 1 left side of the machine. To access the recovery bottle, remove the left side panel. See page 100.
MAINTENANCE AND LUBRICATION Engine Cooling System WARNING Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the pressure cap. Radiator Coolant Level (ATP 500) 2 NOTE: This procedure is required only if the cooling system has been 1 drained for maintenance and/or repair. However, if the recovery bottle has run dry, the level in the radiator should be inspected and coolant added if necessary. 1.
MAINTENANCE AND LUBRICATION Adjustments Brakes The front brakes are hydraulic disc brakes, activated by moving the brake lever toward the handlebar. These brakes are self-adjusting. WARNING 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 accident or severe injury.
MAINTENANCE AND LUBRICATION Adjustments Auxiliary Brake The auxiliary brake is a hydraulic disc brake. The rear brake system is self-adjusting and requires no maintenance other than periodic checks of the pads for wear. Pads should be changed when worn to 3/64″ (.1 cm), which is about the thickness of a U.S. dime. Inspect the brake disc spline and pad wear surface for excessive wear. Your vehicle’s auxiliary brake system is intended to be used as a backup for the main brake system.
MAINTENANCE AND LUBRICATION Adjustments 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. Toe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8″ to 1/4″ toe out. 1. Set the handlebars in a straight-ahead position.
MAINTENANCE AND LUBRICATION Adjustments Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Camber and Caster The camber and caster are non-adjustable. Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster (1) either clockwise or counterclockwise to increase or decrease spring tension.
MAINTENANCE AND LUBRICATION Adjustments Handlebars If desired, the handlebars can be adjusted for rider preference. WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in loss of control and possible serious personal injury or death. Follow the adjustment procedures exactly, or see your Polaris dealer for service. 1. Remove the instrument panel and locate 1 the handlebar bolts (1).
MAINTENANCE AND LUBRICATION Adjustments Carburetor IMPORTANT: Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for each 1000-foot (304.8 m) increase in elevation.
MAINTENANCE AND LUBRICATION Adjustments Throttle Cable Freeplay Throttle cable freeplay is adjusted at the handlebar. 1. Slide the boots (1) off the inline cable adjuster sleeve (2). Loosen the adjuster locknut (3). 2. Turn the adjuster until 1/16″ to 1/8″ freeplay is achieved at the thumb lever. NOTE: While adjusting freeplay, be sure to flip the throttle lever back and forth. 3. Tighten the locknut and slide the boots over the cable adjuster until they touch at the midpoint of the adjuster.
MAINTENANCE AND LUBRICATION Adjustments Side Panel Removal NOTE: Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times. 1. Remove the seat. Step 2 2. Grasp the rear of the side panel near the rear cab. With a quick and firm motion, pull the panel forward and outward to disengage the two rear tabs. 3. Place your hand on top of the side panel behind the fuel tank.
MAINTENANCE AND LUBRICATION Adjustments WARNING Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Maintain proper tire pressure as described on the decal on your ATV and in the specifications section of the owner’s manual beginning on page 126. Always use original equipment size and type when replacing tires.
MAINTENANCE AND LUBRICATION Adjustments Wheel Installation 1. With the transmission in park and the parking brake locked, place the wheel on the wheel hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation. 2. Install the wheel nuts and finger tighten. 3. Lower the vehicle to the ground. 4. Torque the wheel nuts according to the wheel nut torque specifications chart.
MAINTENANCE AND LUBRICATION Adjustments Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized Polaris dealer. Tire Tread Depth Always replace tires when tread depth is worn to 1/8″ (.3 cm) or less. See illustration. 1/8I (.3 cm) WARNING Operating the vehicle with worn tires will increase the possibility of skidding, which could lead to loss of control and serious injury or death.
MAINTENANCE AND LUBRICATION Filter Systems Air Filter Service 1 1. Remove the seat, release the clips, and remove the air 2 box cover. 2. Loosen the clamp and remove the filter. 3. Remove the fabric type pre-filter (1) from the main filter (2). Wash the pre-filter in soapy water, then rinse and let dry. 4. Reinstall the pre-filter over the main filter. (Replace the main filter if necessary.) 5. Reinstall the filter into the air box and tighten the clamp.
Lights MAINTENANCE AND LUBRICATION When servicing a halogen lamp, don’t touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. WARNING Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation. Wash the headlights frequently to maintain lighting quality. Hot components can cause serious burns to skin.
MAINTENANCE AND LUBRICATION Lights High Beam Adjustment The headlight beam can be adjusted to any position desired by turning the adjusting knob on the bottom right side of the headlight pod. 1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m.) from a wall. 2. Remove the two screws on the lower front corners of the headlight pod. 3. Using a small flat-blade screwdriver, push in on the lock tab through the two small openings at the front of the headlight pod. 4.
Lights MAINTENANCE AND LUBRICATION Headlight Housing Replacement 1. Remove the three screws on the headlight pod. 2. Using a small flat-blade screwdriver, push in on the lock tabs through the two small openings at the front of the headlight pod. Lift the pod lightly while depressing the tabs. 3. Lift the pod cover. Disconnect the speedometer harnesses from the 1 speedometer. Unplug the indicator light harness and remove the pod cover. 4. Unplug the headlamp from the wiring harness. 5.
MAINTENANCE AND LUBRICATION Lights Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work, the lamp may need to be replaced. 1. Remove the two screws securing the lens assembly. 2. Pivot the assembly outward. 3. Turn the housing clockwise and remove the bulb. 4. Install a new bulb and reinstall the taillight assembly.
MAINTENANCE AND LUBRICATION Spark Plugs S Use the recommended spark plugs for your model (see SPECIFICATIONS beginning on page 126). S Make sure the electrode gap meets specifications for your model. S Torque spark plugs to 14 ft. lbs. (19 Nm). CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris spark plugs. Spark plug condition is indicative of engine operation.
MAINTENANCE AND LUBRICATION Vehicle Immersion CAUTION If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it’s impossible to take your ATV to a dealer before starting it, follow the steps outlined below. 1. Move the ATV to dry land or at the very least, to water below the foot rests. 2. Turn the fuel valve off. 3. Remove the spark plug. 4. Check the air box and drain if water is present.
MAINTENANCE AND LUBRICATION Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000° F. Allow components to cool sufficiently before proceeding. Remove any combustible materials from the area. Wear eye protection and leather work gloves. Do not stand behind or in front of the vehicle while purging.
MAINTENANCE AND LUBRICATION Recoil Housing To prevent possible engine damage, 1 always drain the recoil housing (1) after operating the ATV in very wet conditions. This should also be done before storing the ATV. NOTE: Water will enter the recoil housing if the starter handle is disengaged from the rope guide when under water. The drain screw is located at the bottom of the recoil housing. Use a wrench to remove the screw. Be sure to reinstall the screw after draining the housing.
Battery MAINTENANCE AND LUBRICATION WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. Battery Removal 1. 2. 3. 4. Disconnect the battery hold-down strap and remove the battery cover. Disconnect the black (negative) battery cable first.
MAINTENANCE AND LUBRICATION Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it’s fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge. NOTE: Battery charge can be maintained by using a Polaris Battery Tendert charger (PN 2871076) or by charging about once a month to make up for normal self-discharge.
Battery MAINTENANCE AND LUBRICATION Battery Charging NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Charge Voltage Action Charge Time* 100% 12.8-13.0 volts None, check at 3 mos. from date of manufacture None required 75%-100% 12.5-12.8 volts May need slight charge, if no charge given, check in 3 months 3-6 hours 50%-75% 12.0-12.5 volts Needs Charge 5-11 hours 25%-50% 11.5-12.
MAINTENANCE AND LUBRICATION Cleaning and Storage See page 121 for the part numbers of Polaris products. Cleaning the ATV Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your ATV can be cleaned much like an automobile. Washing the ATV The best and safest way to clean your ATV is with a garden hose and a pail of mild soap and water.
MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips See page 121 for the part numbers of Polaris products. CAUTION Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period. Clean the Exterior Make necessary repairs and then clean the ATV thoroughly with mild soap and warm water to remove all dirt and grime. Don’t use harsh detergents or high pressure washers.
MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips See page 121 for the part numbers of Polaris products. Fog the Engine Remove the spark plug and add 2-3 tablespoons of Premium 4 Synthetic 0W40 engine oil. To access the plug hole, use a section of clear 1/4” hose and a small plastic squeeze bottle filled with the pre-measured amount of oil.
MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips Battery Storage Remove the battery from the vehicle and ensure that it’s fully charged before placing it in storage. See page 114 for instructions. Engine Anti-Freeze Test engine coolant strength and change if necessary. Coolant should be replaced every two years. Storage Area/Covers Set the tire pressure and safely support the ATV with the tires 1-2” off the ground.
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POLARIS PRODUCTS Part No. Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2871098 Premium 2-Cycle Engine Oil (qt.) 2871721 Premium Gold Synthetic 2-Cycle Oil (qt.) 2871281 Premium 4 Synthetic 0W-40 Engine Oil (4-Cycle)(qt.) Gearcase / Transmission Lubricants 2873602 Premium Synthetic Gearcase Lubricant (qt.) 2871653 Gear Drive Fluid (12 oz.) 2872276 Gear Drive Fluid (2.5 gal.) 2871654 Premium Drive Hub Fluid (8 oz.
TROUBLESHOOTING Drive Belt and Cover Problems Possible Cause Solution Driving the ATV onto a pickup or tall trailer in high range. Shift transmission to low range during loading of the ATV to prevent belt burning. Starting out going up a steep incline. When starting out on an incline, use low range or dismount the ATV (after first applying the park brake) and perform the K-turn as described on page 66. Driving at low RPM or Drive at a higher speed or use low range more frequently.
TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Engine Doesn’t Turn Over Possible Cause Solution Tripped circuit breaker Reset the breaker Low battery voltage Recharge battery to 12.
TROUBLESHOOTING Engine Backfires Possible Cause Solution Weak spark from spark plugs Inspect, clean and/or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non-recommended fuel Replace with new fuel Incorrectly installed spark plug wires See your Polaris dealer Incorrect ignition timing See your Polaris dealer Mechanical failure See your Polaris dealer Engine Runs Irregularly, Stalls or Misfires Possible Weak Spark Cause Solution Fouled or d
TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Turn fuel valve to reserve, refuel Kinked or plugged fuel vent line Inspect and replace Water present in fuel Replace with new fuel Overuse of choke Inspect, clean and/or replace spark plugs Fouled or defective spark plugs Inspect, clean and/or replace spark plugs Worn or defective spark plug wires See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition conn
SPECIFICATIONS ATP 330 4x4 Gross Vehicle Weight Fuel Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Hitch Tongue Capacity Front Rack & Compartment Capacity Rear Box Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Engine Oil Capacity Engine Displacement Bore x Stroke Pilot Jet Main Jet Needle Jet Jet Needle Pilot Screw Alternator Output Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug / Ga
SPECIFICATIONS ATP 330 4x4 Shift Type Side Lever (High, Low, Neutral, Reverse, Park) Gear Reduction - Low 11.57:1 Gear Reduction - Reverse 6.84:1 Gear Reduction - High 4.41:1 Drive Ratio - Front: 3.7:1 Drive Ratio - Final 3.
SPECIFICATIONS ATP 500 4x4 Gross Vehicle Weight Fuel Capacity Towing Rating Unbraked Trailer Towing Capacity* Hitch Tongue Capacity Front Rack & Compartment Capacity Rear Box Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Engine Oil Capacity Coolant Capacity Engine Displacement Bore x Stroke Pilot Jet Main Jet Needle Jet Jet Needle Pilot Screw Alternator Output Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spar
SPECIFICATIONS ATP 500 4x4 Shift Type Side Lever (High, Low, Neutral, Reverse, Park) Gear Reduction - Low 8.66:1 Gear Reduction - Reverse 5.12:1 Gear Reduction - High 3.52:1 Drive Ratio - Front: 3.7:1 Drive Ratio - Final 3.
WARRANTY LIMITED WARRANTY Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty. This warranty begins on the date of purchase. This warranty is transferrable to another consumer during the warranty period through a Polaris dealer.
WARRANTY 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.
WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN 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 warranty or service bulletin coverage if you have any questions.
WARRANTY California Emission Control Warranty Statement Your Warranty Rights and Obligations The California Air Resources Board and Polaris Industries Inc., 2100 Highway 55, Medina, Minnesota 55340 (herein “POLARIS”) are pleased to explain the emission control system warranty on your 2004 and later Large Spark Ignition Engine (herein “LSI engine”).
WARRANTY California Emission Control Warranty Statement Warranty Period This warranty period begins on the date, which the LSI engine is delivered, to the original retail purchaser and ends two years after that date. During this two year period POLARIS warrants to the original retail purchaser and each subsequent purchaser that the LSI engine is free from defect in material and workmanship that can cause the failure of a warranted emission-related part.
WARRANTY California Emission Control Warranty Statement What is Not Covered Under This Warranty This warranty does not cover any emission-related part, which malfunctions, fails, or is damaged due to alterations and/or modifications such as changing, adding, or removing parts. When the LSI engine is being serviced under warranty, POLARIS and any of its authorized dealers shall not be liable for any loss of use of the LSI engine, for any damage to goods, or loss of time or inconvenience.
WARRANTY California Emission Control Warranty Statement Maintenance Schedule b b b Item Hrs/Miles When Remarks Air filter pre-cleaner Air filter main element Engine breather filter Daily Daily Weekly Weekly Inspect, replace if necessary 20 hrs. Monthly Inspect, replace annually Inspect, clean and as needed b Engine oil level/ change 100 hrs./ 1000 mi. 6 mos. Check level daily, break-in service at one month. Change oil more often in cold weather use. b Oil filter 100 hrs./ 1000 mi.
INDEX A E Accessories . . . . . . . . . . . . . . . . . . . . . . 75 Adjustments . . . . . . . . . . . . . . . . . 93-103 Age Restrictions . . . . . . . . . . . . . . . . . . . 7 Air Filter . . . . . . . . . . . . . . . . . . . . . . . 104 All Wheel Drive . . . . . . . . . . . . . . . . . . 47 Auxiliary Brake . . . . . . . . . . . . . . . 42, 94 AWD . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Engine Oil Check . . . . . . . . . . . . . . . . . 82 Equipment Modifications . . . . . . . . . . .
INDEX N S Noise Emission Control System . . . . . . 74 Speedo Mode Switch . . . . . . . . . . . . . . 37 Starting a Cold Engine . . . . . . . . . . . . . 55 Starting a Warm Engine . . . . . . . . . . . . 56 Starting the Engine . . . . . . . . . . . . . 55-56 Steering Assembly . . . . . . . . . . . . . . . . 96 Stop Switch . . . . . . . . . . . . . . . . . . . . . 38 Storage Tips . . . . . . . . . . . . . . . . 117-119 O Odometer . . . . . . . . . . . . . . . . . . . . . . .
