For your nearest Polaris dealer, visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 U.S.A. Part No. 9921792 Rev 02 Printed in U.S.A.
WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our worldwide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. • Snowmobiles • All-terrain vehicles (ATVs) • Quadricycles • RANGER utility vehicles • Victory motorcycles Always follow the instructions and recommendations in this manual.
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.
TABLE OF CONTENTS Know Your Vehicle . . . . . . . . . . . . . . . . . . . . . . . 5 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Features and Controls . . . . . . . . . . . . . . . . . . . 20 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Emission Control Systems . . . . . . . . . . . . . . . 64 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 118 Polaris Products. . . .
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KNOW YOUR VEHICLE As the operator of the vehicle, you are responsible for your personal safety, the safety of others (including your passenger), and the protection of our environment. Read and understand your owner's manual, which includes valuable information about all aspects of your vehicle, including safe operating procedures. Ride responsibly. Know all laws and regulations concerning the operation of this vehicle in your area.
SAFETY Rider Safety 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, on your vehicle or in this manual, alerts you to the potential for injury. WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death.
SAFETY Rider Safety WARNING Failure to follow the warnings in this manual can result in serious injury or death. A Polaris Quadricycle is not a toy and can be hazardous to operate. A collision or rollover can occur quickly, even during routine maneuvers, if you fail to take proper precautions. Read and understand your owner's manual and all warnings before operating a Polaris Quadricycle. Safety Training When you purchased your new Quadricycle, your dealer offered a hands-on safety training course.
SAFETY Rider Safety WARNING Serious injury or death can result if you do not follow the instructions and procedures listed here and throughout this manual. Read and understand all warnings, cautions and operating procedures in this manual and on the safety labels before operating the Quadricycle. Never operate a Quadricycle without proper instruction. Take a training course. Beginners should receive training from a certified instructor.
Rider Safety SAFETY Always wear an approved helmet that fits properly. Wear eye protection (goggles or face shield), gloves, boots, long sleeves and long pants. Never consume alcohol or drugs before or while operating a Quadricycle. Never operate at excessive speeds. Travel and turn at speeds appropriate for the terrain, visibility, operating conditions and your experience. Never attempt jumps or other stunts.
SAFETY Rider Safety Always inspect your Quadricycle before each use to verify that it's in safe operating condition. Follow the inspection and maintenance procedures outlined in this manual. See page 43. Keep both hands on the handlebars. Keep both feet on the footrests. A passenger should always be seated in the passenger seat with both feet on the footrests and both hands on the passenger grab handles at all times. The passenger should never hold on to the operator.
Rider Safety SAFETY If a Quadricycle has been involved in an accident, always have an authorized Polaris dealer inspect the entire vehicle for possible damage, including (but not limited to) brake, throttle and steering systems. Always follow the procedures outlined in this manual for driving on hills. See page 50. Never operate on hills too steep for the Quadricycle or for your abilities. Practice on smaller hills before attempting larger hills. Avoid climbing hills steeper than 15°.
SAFETY Rider Safety Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never back down a hill. See page 54. Always follow the procedures outlined in this manual for operating over obstacles. See page 59. Always follow the procedures outlined in this manual for operating on slippery or loose surfaces. Use extra caution. Always avoid skidding or sliding. See page 58.
Rider Safety SAFETY Always follow the procedures outlined in this manual for driving in reverse. See page 61. Always use the size and type of tires specified for your vehicle. Maintain the proper tire pressure. Never modify a Quadricycle through improper installation or use of accessories. Never exceed the stated load capacity for your vehicle. Cargo must be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for carrying cargo or towing.
SAFETY Rider Safety Never operate the Quadricycle on a frozen body of water. Operating on paved surfaces may affect the handling and control of the Quadricycle and could result in loss of control. Avoid sudden turns or swift movement of the handlebars. Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting. Always unlock the steering before starting the engine. See page 27. Hot components can cause serious burns and fire.
SAFETY Safety Decals and Locations Warning decals have been placed on the vehicle 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. The following pages repeat the information found on each decal.
SAFETY Safety Decals and Locations Reverse Override Alert Front Rack Warning + + Clutch Cover Alert + + Rear Rack Warning + Tire Pressure/ Load Alert Tire Pressure/Load Alert TIRE PRESSURE IN PSI (KPa): FRONT 5 (34.5) REAR 5 (34.5) MAXIMUM WEIGHT CAPACITY 568 LBS. (258 KG) INCLUDES WEIGHT OF OPERATOR, PASSENGER, CARGO AND ACCESSORIES. Read Owner's Manual for more detailed loading information.
Safety Decals and Locations SAFETY Rack Warning, Front and Rear WARNING DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch. Maximum Rack Loads: Front 90 lbs. (41 kg) Rear 180 lbs. (82 kg) 7172572 Clutch Cover Alert 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.
SAFETY Safe Riding Gear Always wear protective clothing to reduce the chance of injury. Helmet Eye Protection Long Sleeves Gloves Long Pants Boots Helmet 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.
Safe Riding Gear SAFETY 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.
FEATURES AND CONTROLS Switches Mode/Reverse Override Switch Differential Switch Engine Stop Switch Hazard Switch Headlight Switch 4X4 Switch Horn Switch Turn Signal Switch Main Key Switch Mode/Reverse Override Switch Press the switch to toggle through the speedometer display modes (except in reverse). See page 32. To gain additional wheel speed while operating in reverse, press the override switch before opening the throttle. This will cancel the reverse speed limit function.
Switches FEATURES AND CONTROLS Main Key Switch End all electrical power to the vehicle. LIGHTS ON position turns the headlights on. Start the engine. The headlights are not on in this position. After starting the engine, release the key switch to the POSITION LIGHTS ON position. Do not attach a large key fob or key ring to the main switch. It may contact the gas tank cap when turning, causing an interruption to the electrical system and an unexpected engine shut-down during operation.
FEATURES AND CONTROLS Switches 4X4 Switch Use the 4X4 switch to engage ADC 4X4, 4X4 or 2X4. See page 30. Hazard Warning Switch Push the hazard warning switch to cause all turn signal lights to flash simultaneously. Use this feature to alert others of an emergency or other situation requiring caution. 4X4 Switch Hazard Warning Switch Differential Switch Turn Indicators Turn Signal Switch Push the toggle switch either left or right to activate the corresponding turn signal light.
Switches FEATURES AND CONTROLS Differential Switch Use the differential switch to lock and unlock the rear differential. Locked Differential: Operate the vehicle with the switch in the locked position in most conditions. Unlocked Differential: When the differential is unlocked, the inside wheel will rotate independently from the outside wheel during turns. Operate with an unlocked differential only as needed to protect smooth, level surfaces from tire damage.
FEATURES AND CONTROLS Throttle Lever Press the throttle lever to increase engine speed and vehicle movement. Release the lever to reduce engine speed and vehicle movement. WARNING Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation. Check the lever for proper operation before starting the engine. Check occasionally during operation.
Foot Brake FEATURES AND CONTROLS The all-wheel foot brake is located on the right footrest. The foot brake operates both front and rear brakes. Press the brake pedal down with your foot to apply the all-wheel brakes. If the rear wheels begin to skid or slide while using the foot brake, reduce brake pressure. Foot Brake Hand Brake Lever The hand brake operates both front and rear brakes. Squeeze the brake lever toward the handlebar to apply the all-wheel brakes.
FEATURES AND CONTROLS Parking Brake Locking the Parking Brake 1. Place the transmission in PARK. 2. Squeeze the brake lever toward the handlebar. 3. Push the parking brake lock forward to engage the lock. Release the brake lever. 4. To release the parking brake lock, squeeze and release the brake lever. WARNING Operating the Quadricycle while the parking brake is engaged could result in an accident and serious injury or death. Always release the parking brake lock before operating.
Steering Lock FEATURES AND CONTROLS Lock the steering to prevent unauthorized use or theft of the vehicle. 1. Turn the handlebars to the full right position. NOTE: The handlebars may also be locked in the full left position. 2. Insert the steering lock key and turn it clockwise. 3. Remove the key. NOTE: Place the steering lock keys in a safe place. The lock must be replaced if the keys are lost. 4. Reverse the procedure to unlock the steering.
FEATURES AND CONTROLS Fuel Tank Cap Remove the fuel tank cap to add fuel to the fuel tank. Use either leaded or unleaded gasoline with a minimum pump octane of 87. Do not use E-85 fuel. Fuel Filter The in-line fuel filter should be replaced by your dealer after every 100 hours of operation or annually. Do not attempt to clean the fuel filter.
FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector is located on the right side of the vehicle. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park Whenever the vehicle is left unattended, always place the transmission in PARK. The transmission is locked when it’s in PARK. Gear Selector Shifting gears with the engine speed above idle or while the vehicle is moving can cause transmission damage.
FEATURES AND CONTROLS All Wheel Drive (4X4) System The All Wheel Drive system is controlled by the 4X4 switch. ADC 4X4 When the switch is on ADC 4X4, the ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 31. 4X4 When the switch is on 4X4, the vehicle is in 4X4, and the 4X4 indicator light in the instrument cluster will be on.
FEATURES AND CONTROLS All Wheel Drive (4X4) System Engaging 4X4 The 4X4 switch may be turned on or off while the vehicle is moving. 4X4 will not engage until engine speed is below 3100 RPM. 4X4 remains engaged until the switch is turned off. There is no limit to the length of time the vehicle may remain in 4X4. If the switch is turned off while the demand drive unit is engaged, it will not disengage until the rear wheels regain traction.
FEATURES AND CONTROLS Instrument Cluster The instrument cluster senses vehicle speed from the transmission. The instrument cluster measures distance in miles or kilometers, as well as hours of operation. It also includes a reverse speed limiter function that limits the vehicle's speed to approximately 11-14 km/h. Refer to page 20 for additional information.
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 electronic speedometer. If this occurs, take the vehicle to your Polaris dealer for proper diagnosis. 1.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes Use the MODE button to toggle through the mode options. The reverse override button is also the MODE button. See page 20. NOTE: The transmission cannot be in reverse when using this feature. Odometer Mode The odometer records the miles or kilometers traveled by the Quadricycle. Trip Meter Mode The trip meter records the miles or kilometers traveled by the Quadricycle on each trip if it's reset before each trip.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when the gauge is in the diagnostic mode. To exit the diagnostic mode, turn the key switch off and on. Any movement of the tires will also cause the gauge to exit the diagnostic mode. To enter the diagnostics mode: 1. Turn the key switch off and wait 10 seconds. 2. Lock the parking brake. 3. Place the transmission in neutral. 4. Hold the mode/reverse override button and turn the key switch on.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Battery Voltage Screen View this screen to check battery voltage level. Tachometer Screen View the tachometer to check engine speed. 4X4 Diagnostic Screen The gauge indicates whether or not current is flowing through the 4X4 coil (only on models with switchable 4X4). This screen is for informational purposes only. Please see your dealer for all major repairs.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Programmable service interval To enable or disable the service interval: 1. Enter the diagnostic mode. 2. Toggle to the service interval screen. 3. Press and hold the mode button for about 7 seconds, until either ON or OFF appears in the Rider Information Center, depending on your preference. To reset the service interval: 1. Enter the diagnostic mode. 2. Toggle to the service interval screen. 3.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Miles/Kilometers toggle The display in the tripmeter and odometer can be changed to display either standard or metric units of measurement. 1. Enter the diagnostic mode. 2. Toggle to the screen that displays either kilometers (KM) or miles (MP). 3. Press and hold the mode button until the letters flash, then press and release the button once. When the display stops flashing, the mode has been set.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes 3. The Check Engine icon will blink once, pause, then blink twice (blink code 12) to begin the diagnostic sequence. The EFI module is now searching for blink codes. If a code exists, the Check Engine icon will flash the code. 4. Count the number of times the Check Engine icon flashes.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Blink Code 12 22 22 25 31 31 36 36 37 37 41 41 42 42 44 45 46 47 47 51 51 52 52 55 55 56 56 58 58 59 59 63 63 72 73 73 74 74 61 40 Failure Description BEGIN SEQUENCE Throttle Position Sensor Low Throttle Position Sensor High Gear Sensor Signal System Voltage Low System Voltage High Ignition Coil A Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground Ignition Coil A Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Ba
OPERATION Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions. • Use extreme caution whenever handling gasoline. • Refuel with the engine stopped. Refuel outdoors or in a well-ventilated area. • Never fill a fuel container while it's on the vehicle. Static electricity between the rack and container could cause a spark. • Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. • Do not overfill the tank.
OPERATION Break-In Period The break-in period for your new Polaris Quadricycle is 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 will increase the life and performance of your Quadricycle more than following the procedures for a proper break-in. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components.
OPERATION Pre-Ride Checklist Item Remarks Page Hand brake/lever travel Ensure proper operation 84 Foot brake Ensure proper operation 84 Brake fluid Ensure proper level 84 Passenger seat latch Ensure latch is secure 29 Front suspension Inspect, lubricate if necessary 69 Rear suspension Inspect, lubricate if necessary 69 Steering/steering lock Unlock the steering; ensure free operation 27 Steering Ensure free operation - Tires Inspect condition and pressure 89 Wheels/fasteners
OPERATION Starting the 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. Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Sit on the vehicle.
Cold Weather Operation OPERATION Internal engine condensation increases as outside temperatures decrease. If the vehicle is used year-round, check the oil level frequently. A rising oil level could indicate condensation in the bottom of the oil tank, which can lead to engine damage. Any condensation must be drained. Always operate the engine long enough to reach operating temperature, which reduces condensation.
OPERATION Driving Procedures 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 46 Wear protective riding gear. See page 18. Perform the pre-ride inspection. See page 43. Place the transmission in PARK. Mount the vehicle from the left side. Sit upright. Keep your feet on the footrests. Keep both hands on the handlebars. Start the engine and allow it to warm up. Apply the brakes. Shift the transmission into gear. Check your surroundings and determine your path of travel. Release the brakes.
Turning the Vehicle OPERATION 1. Before turning, activate a turn signal to alert others of your intentions. Activate the left signal before a left turn. Activate the right signal before a right turn. 2. Steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. Use the same leaning technique for turning in reverse. 3. Never turn quickly when carrying a passenger or cargo. 4.
OPERATION Driving with a Passenger Never allow anyone under 16 years of age to operate this vehicle. Never allow anyone under 12 years of age to ride as a passenger on this 2-up Quadricycle. Never carry more than one passenger on this 2-up Quadricycle. 1. Make sure the passenger is at least 12 years of age and is tall enough to comfortably reach the footrests and grab handles. 2. Do not carry a passenger until you have at least two hours of driving experience with this vehicle. 3.
Driving with a Passenger OPERATION 7. Mount the vehicle from the left side. 8. After the operator is seated, the passenger should mount the vehicle from the left side. NOTE: Allow a passenger to ride only in the approved passenger seat with both feet on the footrests and both hands on the passenger grab handles at all times. The passenger should never hold on to the operator. 9. Drive slowly. Control may be more difficult with a passenger on board. Allow more time and distance for braking. 10.
OPERATION Driving Uphill 15° Maximum Whenever traveling uphill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 31. 2. Avoid steep hills (15° maximum). 3. Avoid hills with slippery or loose surfaces. 4. Keep both feet on the footrests. 5. Shift body weight uphill. 6. Drive straight uphill. 7. Proceed at a steady rate of speed to avoid stalling. 8. Be alert. Be prepared to take emergency action. This may include dismounting quickly. 9.
Driving Uphill OPERATION If all forward speed is lost: Keep your weight uphill. If the vehicle begins rolling downhill, never apply engine power. Never apply the brakes aggressively while rolling backwards. 1. Apply the brakes gradually. 2. When fully stopped, lock the hydraulic parking brake. 3. A passenger should dismount first.The operator should dismount last. Dismount on the uphill side, or on the left side if the vehicle is pointed straight uphill. 4. Use the K-turn to turn around. See page 54.
OPERATION Driving on a Sidehill (Sidehilling) Polaris does not recommend crossing the side of a hill (sidehilling). If sidehilling is unavoidable, follow these precautions: 1. Slow down. 2. If operating in 2X4 mode, make sure the differential is locked ( ). 3. Avoid hills with slippery or loose surfaces. 4. Avoid crossing the sides of steep hills. 5. Do not cross a hillside with a passenger on board. Ask the passenger to dismount and walk across the hillside. 6. Shift your weight uphill. 7.
Driving Downhill OPERATION When driving downhill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 31. 2. Avoid hills with slippery or loose surfaces. 3. Never drive downhill at high speed. Slow down. 4. Drive straight downhill. 15° Maximum Avoid driving downhill at an angle, which can cause the vehicle to pitch sharply to one side. 5. Shift your weight rearward. 6. Apply the brakes slightly to aid in slowing.
OPERATION Turning Around on a Hill (K-Turn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 2.4 m 1. Stop the vehicle. Keep your weight uphill. 2. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 31. 3. Lock the hydraulic parking brake. 4. Leave the transmission in forward gear. Turn the engine off. 5. A passenger should dismount first.The operator should dismount last.
Turning Around on a Hill (K-Turn) OPERATION 9. Lock the hydraulic parking brake. 10. Remount from the uphill side. Keep your weight uphill. NOTE: 11. 12. 13. 14. A passenger should not remount until the vehicle returns to level ground. Apply the foot brake. With the transmission still in forward, start the engine. Squeeze and release the brake lever to release the parking brake. Release the foot brake and drive slowly downhill.
OPERATION Driving Through Water Maximum Depth Follow these procedures when driving through water: 1. Check water depth and current before crossing. 2. Choose a crossing where both banks have gradual inclines. 3. Drive slowly. Avoid rocks and obstacles. 4. Avoid operating in water deeper than the bottom of the footrests. If it's unavoidable, travel slowly, balance your weight carefully and avoid sudden movements. Maintain a slow and steady forward motion.
Driving Through Water OPERATION If your vehicle becomes fully immersed, and it's impossible to take it to a dealer before starting it, follow the steps described on page 100. Have the vehicle serviced by your dealer promptly. Always follow the procedures outlined in this manual for driving through water. Never drive through deep or fast-flowing water. If the vehicle stops while fully submerged, major engine damage can result if the machine is not thoroughly inspected.
OPERATION Driving on Slippery Surfaces Whenever driving on slippery or loose surfaces such as wet trails, gravel, snow or ice, follow these precautions: 1. Slow down before driving onto slippery surfaces. 2. Engage 4X4 before wheels begin to lose traction. 3. Be alert. 4. Watch the trail. 5. Avoid quick, sharp turns. 6. Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward. 7. Never apply the brakes during a skid.
Driving Over Obstacles 1. 2. 3. 4. 5. OPERATION Always check for obstacles before operating in a new area. Be alert. Watch the terrain. Use extra caution. Never operate over large obstacles. Avoid hazards such as logs, rocks and low branches. Always have a passenger dismount before operating over an obstacle. Always follow the procedures outlined in this manual for operating over obstacles.
OPERATION Parking on an Incline Avoid parking on an incline. If it's unavoidable, follow these precautions: 1. Stop the engine. 2. Place the transmission in PARK. 3. Always block the rear wheels on the downhill side.
Driving in Reverse OPERATION Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle before backing. Be aware that a passenger can obstruct your view. 2. Avoid backing downhill. 3. Drive slowly. Apply the brakes lightly for stopping. 4. Avoid turning at sharp angles. 5. Never open the throttle suddenly. 6. Do not use the override switch unless additional power is required for vehicle movement. Use with caution.
OPERATION Hauling Cargo Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo. • Read and understand the load distribution warnings listed on the vehicle warning labels. • Never exceed the maximum weight capacity for this vehicle. When calculating, include the weight of the operator, passenger, accessories, loads in the rack or box and the load on the trailer tongue.
OPERATION Hauling Cargo 2/3 1/3 Towing Loads Towing is approved OFF-ROAD ONLY. Operating a Quadricycle/trailer combination on public roads is prohibited. See your Polaris dealer about configuring the vehicle to be certified to tow a trailer on-road. Do not tow any trailer on a grade steeper than 15°. If towing a load, reduce rear rack cargo weight by the amount of tongue weight.
EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with governmental noise level requirements. Spark Arrestor Your Polaris vehicle has a spark arrestor that was designed for on-road and off-road operation. It is required that this spark arrestor remain installed and functional when the vehicle is operated. Exhaust Emission Control System Exhaust emissions are controlled by engine design.
Periodic Maintenance Chart MAINTENANCE Maintenance intervals in the following chart are based upon average riding conditions. Vehicles subjected to severe use must be inspected and serviced more frequently. The programmable service interval mode on the instrument cluster will help determine when maintenance service is due. See page 32. Record maintenance and service in the Maintenance Log beginning on page 128. NOTE: Service and adjustments are important for proper vehicle operation.
MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key X Perform these operations more often for vehicles subjected to severe use. E Emission-related service Q Have an authorized Polaris dealer perform these services. WARNING Improperly performing the procedures marked with a Q could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. Perform all services at whichever maintenance interval is reached first.
Periodic Maintenance Chart Item Maintenance Interval X Brake pad wear Q Battery Remarks (whichever comes first) Hours Calendar X Air filter, E main element MAINTENANCE Kilometers - Weekly - Inspect; replace as needed 10 Monthly 160 Inspect periodically 20 Monthly 320 Check terminals; clean; test X Demand drive fluid 25 Monthly 400 Inspect level; change yearly X Rear gearcase oil (if equipped) 25 Monthly 400 Inspect level; change yearly X Transmission oil 25 Monthly 400 Ins
MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Kilometers Q Valve clearance 100 12 M 1600 Inspect; adjust Q Fuel system 100 12 M 1600 Check for leaks at tank cap, lines, filter, pump; replace lines every 2 years X Radiator 100 12 M 1600 Inspect; clean external surfaces X Cooling hoses 100 12 M 1600 Inspect for leaks X Engine mounts 100 12 M 1600 Inspect 100 12 M 1600 Inspect Q Spark plug 100 12 M 1600 In
MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 65. Items not listed in the chart should be lubricated at the General Lubrication interval. NOTE: The a-arms and upper control arms are lubricated at the factory, and no additional lubrication will be needed. However, if these components are subjected to severe use, grease zerks have been provided for additional lubrication at the user's discretion.
MAINTENANCE Engine Oil Oil Recommendations Always change the oil filter whenever changing oil. Polaris recommends the use of Polaris PS-4 PLUS Performance Synthetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if Polaris oil is not used. Always use 2W-50 oil. Follow the manufacturer's recommendations for ambient temperature operation Mixing brands or using a non-recommended oil may cause serious engine damage. Always use a recommended oil.
Engine Oil MAINTENANCE Oil Level 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Lift the lever lock. Remove the dipstick. Wipe it dry with a clean cloth. 4. Reinstall the dipstick completely, but do not lock it. Dipstick 5. Remove the dipstick and check the oil level on the top side of the dipstick. 6. Maintain the oil level in the safe range. Do not overfill. Check Level on Top Side NOTE: The oil level will read higher on the bottom side of the dipstick.
MAINTENANCE Engine Oil Oil and Filter Change CAUTION Hot oil may result in serious burns. Do not allow hot oil to contact skin. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Start the engine. Allow it to idle for 2-3 minutes. 4. Stop the engine. 5. Clean the area around the drain plug. Drain Plug Location to front 6. Remove the drain plug. Drain the oil into a drain pan. 7. Clean the drain plug. Reinstall the drain plug with a new sealing washer. 8.
Engine Oil MAINTENANCE Oil and Filter Change 9. Place towels under the oil filter. Using an oil filter wrench, turn the filter counterclockwise to remove it. 10. Clean the filter sealing area on the crankcase. 11. Lubricate the filter o-ring. Check to make sure the o-ring is in good condition. 12. Install the new oil filter. After the filter contacts the crankcase surface, turn it 1/2 turn by hand. 13. Remove the dipstick. 14. Add 1.9 liters of recommended oil. 15. Place the transmission in PARK. 16.
MAINTENANCE Transmission Oil Maintain the oil level at the bottom of the fill plug hole threads. Use the recommended oil. See page 120 for the part numbers of Polaris products. Transmission Oil Recommendations Lubricant Oil Change Capacity Fill Plug Torque Drain Plug Torque Premium AGL Synthetic Gearcase Lubricant 948 ml 30 N-m 30 N-m Transmission Oil Level 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Remove the fill plug. 4. Check the oil level.
Transmission Oil MAINTENANCE Transmission Oil Change 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Remove the fill plug. 4. Remove the drain plug. 5. Drain the oil into a drain pan. 6. Clean the drain plug. 7. Reinstall the drain plug. Torque to specification. See page 74. 8. Add the recommended oil. See page 74. 9. Reinstall the fill plug. Torque to specification. See page 74. 10. Check for leaks. 11. Discard used oil properly.
MAINTENANCE Front Gearcase (Demand Drive) Fluid Fluid Recommendations Gearcase Lubricant Capacity Fill Plug Torque Drain Plug Torque Demand Drive Unit Demand Drive LT Premium Fluid 275 ml 11-14 N-m 15 N-m Use the recommended fluid. Use of other fluids may result in improper operation of components. See page 120 for the part numbers of Polaris products. Maintain the fluid level at the bottom of the fill hole threads. Fill Plug Fill Level Drain Plug Fluid Level 1.
MAINTENANCE Front Gearcase (Demand Drive) Fluid Fluid Change 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Remove the fill plug. 4. Remove the drain plug. Drain the fluid into a drain pan. 5. Clean the drain plug. 6. Reinstall the drain plug. Torque to specification. See page 76. 7. Add the recommended fluid. 8. Reinstall the fill plug. Torque to specification. 9. Check for leaks. 10. Discard used oil properly.
MAINTENANCE Active Descent Control (ADC) Fluid The ADC fluid reservoir is located under the front box. The reservoir cap is yellow. We recommend the use of Polaris ADC Fluid. See page 120 for the part numbers of Polaris products. Fluid Level 1. Position the vehicle on a level surface. 2. Open the front box cover. 3. Open the access door. 4. View the fluid level in the reservoir. 5. Remove the cap and add the recommended fluid as needed. NOTE: DO NOT use brake fluid. 6.
MAINTENANCE Active Descent Control (ADC) Fluid Fluid Change 1. Position the vehicle on a level surface. Before performing the fluid change, allow the vehicle to sit for at least 30 minutes. 2. Thoroughly clean the areas around and on the ADC reservoir and bleeder valves (one on each side of the differential). 3. Remove the reservoir cap and diaphragm assembly. Use a shop towel or suction tool to remove debris from the fluid and reservoir.
MAINTENANCE Cooling System Any time the cooling system has been drained for maintenance or repair, replace the coolant with a fresh mixture of antifreeze and water. Drain the cooling system every two years. Add fresh coolant. Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/ coolant and distilled water. Polaris Premium 60/40 is premixed and ready to use. Do not dilute with water.
MAINTENANCE Cooling System Radiator Coolant WARNING Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot. 1. Open the front box cover. 2. Open the access door. 3. Remove the radiator pressure cap. 4. If coolant is not visible, slowly add coolant through the radiator filler neck. 5. Reinstall the pressure cap. 6. Secure the access door and box cover. NOTE: Use of a non-standard pressure cap will not allow the recovery system to function properly.
MAINTENANCE Brake Fluid Check brake fluid levels for both brake systems before each ride. Always maintain brake fluid at the recommended level. Do not overfill. The brakes should feel firm when they're applied. Spongy or weak brakes may indicate a fluid leak or low fluid level. A low fluid level may also mean that brake pads are worn and need to be replaced. Do not operate the vehicle with spongy or weak brakes. See your dealer for service.
Brake Fluid MAINTENANCE Hand Brake The master cylinder is located on the left handlebar. Maintain the fluid level 6 mm below the top edge of the master cylinder. Do not overfill. 1. Position the vehicle on a level surface. Make sure the handlebars are straight. 2. View the fluid level through the indicator window (eye) on the top of the master cylinder. Master Cylinder Indicator Window Full Low NOTE: The eye will appear dark when the fluid level is full. When fluid is low, the eye will be clear.
MAINTENANCE Brakes The front and rear brakes are hydraulic disc brakes, activated by applying the foot brake. The handlebar brake is also hydraulic. Both brake systems are self-adjusting. Brake Inspections Perform the following checks to keep the brake systems in good operating condition. Check more often if brakes are used heavily under normal operation. 1. Always keep brake fluid at an adequate level. See page 82. 2. Check the brake systems regularly for fluid leaks. 3.
MAINTENANCE Toe Alignment WARNING Do not attempt to adjust alignment. All steering adjustments should be performed by an authorized Polaris dealer. Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 3-6 mm toe out. 1. Position the vehicle on a level surface. 2. Place the handlebars in a Stand straight-ahead position. 3. Tie a length of string String between two stands as shown in the illustration.
MAINTENANCE Handlebar Adjustment 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. Follow the adjustment procedures exactly, or see your Polaris dealer for service. 1. Remove the upper headlight pod. 2. Loosen the four handlebar bolts. 3. Adjust the handlebar to the desired height.
Side Panel Removal MAINTENANCE 1. Remove the seat. 2. Grasp the rear of the side panel near the rear cab. 3. With a firm motion, pull the panel outward to disengage the side panel from the grommet. 4. Pull the panel downward and rearward to remove it. 5. When reinstalling side panels, align the fasteners and press firmly to secure them. Footwell Removal Screws 1. Remove the six screws on the bottom of the footwell. 2.
MAINTENANCE Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar. 1. Locate the throttle cable adjuster at the handlebar. 2. Squeeze the end of the rubber boot and slide it far enough to expose the end of the inline cable adjuster. Boot 3. Loosen the adjuster lock nut. Lock Nut Adjuster 4. Rotate the boot to turn the adjuster until 1.6-3.2 mm of freeplay is achieved at the thumb lever. NOTE: Move the throttle lever back and forth while adjusting. 1.6-3.2 mm 5. Tighten the lock nut.
MAINTENANCE Tires Refer to the specifications section beginning on page 118 for recommended tire type, size and pressure. WARNING Operating your vehicle with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident. • Maintain proper tire pressure as described on the decal on your vehicle and in the specifications section of the owner's manual. • Use only original equipment size and type when replacing tires.
MAINTENANCE Tires Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loosened for maintenance service.
Tires MAINTENANCE Always use original equipment size and type when replacing tires. Install wheels properly. Wheel Removal/Installation 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Loosen the wheel nuts slightly. 4. Place a suitable stand under the footrest frame to raise the wheel slightly off the ground. 5. Remove the wheel nuts. 6. Remove the wheel. 7. Place the wheel on the hub. 8. Install the wheel nuts finger tight. 9. Lower the vehicle to the ground. 10.
MAINTENANCE Air Filter Always clean and replace the air and breather filters at the intervals outlined in the Periodic Maintenance Chart beginning on page 65. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Remove the seat. 4. Release the air box cover clips. 5. Remove the air box cover. 6. Loosen the hose clamp. 7. Remove the filter. 8. Remove the pre-filter from the filter. Pre-Filter 9. Wash the pre-filter in soapy water. Rinse and air dry.
Breather Filter/Hose MAINTENANCE The breather filter is on the hose between the engine and air box. 1. Remove the left side panel. See page 87. 2. Remove the hose clamps from the filter and pull the filter out of the hoses. 3. Inspect the filter for debris. Blow gently through the filter in the direction of the arrow to check for clogging. Replace a damaged or clogged filter. Breather Filter 4. Check the hoses for cracks, deterioration, abrasion, or leaks. Replace as needed. 5.
MAINTENANCE Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. 1. Position the vehicle on a level surface. The headlight should be approximately 7.6 m from a wall. 2. Place the transmission in PARK. 3. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. 7.6 m X X NOTE: Include rider weight on the seat when measuring. 4. Start the engine.Turn the headlight switch to high beam. 5.
MAINTENANCE Lights WARNING Poor lighting can result in loss of control or an accident. Lights become dirty during normal operation. Wash the headlights and taillights frequently. Hot components can cause serious burns to skin. Do not service the headlamps until they've cooled. Headlight/Position Light Lamp Replacement When servicing a halogen lamp, do not 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.
MAINTENANCE Lights Taillight Lamp Replacement 1. Place the transmission in PARK. 2. Rotate the taillight socket counterclockwise to remove it. 3. Remove the lamp. 4. Apply dielectric grease to the socket. 5. Install the new lamp. Test the lamp for proper operation. 6. Reinstall all components in reverse order. Front Turn Signal Lamp Replacement 1. Place the transmission in PARK. 2. Remove the lens attachment screw. 3. Rotate the lamp to remove it. 4. Install the new lamp. 5. Reinstall the lens.
Fuse Replacement MAINTENANCE If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. NOTE: Spare fuses are provided in a compartment on the top of the access door. 1. Open the front box cover. 2. Open the access door. 3. Remove the suspect fuse from the fuse panel. Install a new fuse with the same amperage. 4. Secure the access door. 5. Secure the box cover.
MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 118 for the recommended spark plug type and gap for your vehicle. Torque spark plugs to specification. Plug Condition Torque Specification New Spark Plug 12-15 N-m Previously Installed Spark Plug 23-27 N-m Spark Plug Inspection Spark plug condition is indicative of engine operation.
Spark Plugs MAINTENANCE Spark Plug Removal A hot exhaust system and engine can cause serious burns. Wear protective gloves when removing a spark plug for inspection. 1. Remove the spark plug cap. 2. Use the spark plug wrench to remove the spark plug. Turn the plug counterclockwise to remove it. 3. Inspect the electrodes for wear and carbon buildup. Replace worn or fouled plugs. Verify that the gap is at specification before installation. 4. Reinstall the spark plug. Torque to specification. See page 98.
MAINTENANCE Vehicle Immersion If your vehicle has been totally submerged in water and it's impossible to have it serviced before further operation, perform the following procedure. If the vehicle stops while fully submerged, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. 1. Move the vehicle out of the water. 2. Remove the spark plug. 3. Drain any water found in the air box.
Vehicle Immersion MAINTENANCE 4. Turn the ignition key past the POSITION LIGHTS position to engage the starter. Engage the starter for only 2-3 seconds. 5. Dry the spark plug. Reinstall the plug or install a new plug. 6. Torque to specification. See page 98. 7. Attempt to start the engine. If necessary, repeat the drying procedure. 8. Have the vehicle serviced by your dealer promptly, whether you succeed in starting it or not.
MAINTENANCE Spark Arrestor Occasionally, the spark arrestor may accumulate carbon, which can restrict the exhaust if left unattended. Purge the spark arrestor. WARNING Allow components to cool sufficiently before servicing. The exhaust system can get extremely hot. Never run the engine in an enclosed area or indoors. Exhaust contains poisonous carbon monoxide gas. Never go under the vehicle while it's inclined. Remove any combustible materials from the area. Wear eye protection and leather work gloves.
Spark Arrestor MAINTENANCE 6. If carbon comes out of the exhaust, cover or plug the exhaust outlet. Wear protective gloves. 7. Lightly tap on the exhaust pipe with a rubber mallet while repeating step 5. 8. If particles are still suspected to be in the muffler, elevate the rear of the vehicle 30 cm higher than the front. Block the wheels. 9. Place the transmission in 30 cm PARK. Repeat steps 5 to 7 until no more particles are expelled. 10. Stop the engine. Allow the arrestor to cool. 11.
MAINTENANCE PVT System Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components. The PVT system rotates at high speeds, creating large amounts of force on clutch components. Extensive engineering and testing has been conducted to ensure the safety of this product.
PVT System MAINTENANCE PVT Drying There may be some instances when water is accidently ingested into the PVT system. Dry it out before operating. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Remove the drain plug. Allow the water to drain completely. Reinstall the drain plug. 4. Start the engine. 5. Apply varying throttle for 10-15 seconds to expel the moisture and air-dry the belt and clutches. NOTE: Do not hold the throttle wide open for more than 10 seconds. 6.
MAINTENANCE Battery Your vehicle may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can be identified by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery. Always keep battery terminals and connections free of corrosion. If cleaning is necessary, remove corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water.
MAINTENANCE Battery 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. 5. 6. 7. Place the transmission in PARK. Disconnect the battery hold-down strap. Remove the battery cover (if equipped). On conventional batteries, remove the battery vent tube.
MAINTENANCE Battery Battery Installation 1. Ensure that the battery is fully charged. 2. Place the battery in the battery holder. 3. With conventional batteries, install the battery vent tube (sealed batteries do not have a vent tube). The vent tube must be free of obstructions and securely installed. Route the tube away from the frame and vehicle body to prevent contact with electrolyte.
Battery Battery Fluid (Conventional Battery) MAINTENANCE Lower Mark Upper Mark Check the battery fluid level often. Maintain the fluid level between the upper and lower level marks. Add only distilled water. Tap water contains minerals that are harmful to a battery. Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during charging. See page 107. 2.
MAINTENANCE Battery Battery Charging (Sealed Battery) For a refresh charge, follow all instructions carefully. 1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher. 2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less until battery voltage is 12.8 or greater. NOTE: When using an automatic charger, refer to the charger manufacturer's instructions for recharging.
Cleaning and Storage MAINTENANCE Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components. 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. 1.
MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components and could remove paint and decals. Avoid directing the water stream at the following items: • Wheel bearings • Radiator • Transmission seals • Brakes • Cab and body panels • Labels and decals • Electrical components and wiring NOTE: If warning and safety labels are damaged, contact your Polaris dealer for free replacement.
Cleaning and Storage MAINTENANCE Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a "like new" appearance for many years. NOTE: Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned. Clean chrome wheels more often if they're exposed to salt or other corrosive elements. 1. Wash chrome wheels frequently. Use a mild detergent.
MAINTENANCE Cleaning and Storage Storage Tips Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period. Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. See page 111. Stabilize the Fuel 1. Fill the fuel tank. 2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount.
Cleaning and Storage MAINTENANCE Storage Tips Fluid Levels Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 65. • Demand drive unit (front gearcase) • ADC fluid (change every two years) • Rear gearcase (if equipped) • Transmission • Brake fluid (change every two years and any time the fluid looks dark or contaminated) • Coolant (test strength/fill) Fog the Engine 1. Treat the fuel system with Polaris Carbon Clean. See page 114. 2.
MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 65. Battery Storage See pages 108-109 for storage and charging procedures. Storage Area/Covers 1. Set the tire pressure and safely support the vehicle with the tires slightly off the ground. 2. Be sure the storage area is well ventilated. 3. Cover the vehicle with a genuine Polaris cover.
Transporting the Vehicle MAINTENANCE Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place the transmission in PARK. 3. Secure the fuel cap, oil cap and seat. 4. Remove the key to prevent loss during transporting. 5. Always tie the frame of the Quadricycle to the transporting unit securely with suitable straps or rope. Do not attach tie straps to the front A-arm bolt pockets.
SPECIFICATIONS Sportsman 800 Touring Quadricycle Maximum Weight Capacity Dry Weight Front Rack/Storage Box Capacity Rear Rack Capacity Receiver Hitch Tongue Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Fuel Capacity Engine Oil Capacity Coolant Capacity Demand Drive Fluid Capacity Transmission Oil Capacity Engine Displacement Bore x Stroke Alternator Output Compression Ratio Fuel System Ignition Sy
SPECIFICATIONS Sportsman 800 Touring Quadricycle Transmission Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Tires/Pressure, Front Tires/Pressure, Rear Brake, Hand Brake, Foot Brake, Parking Headlight Taillights Brake Light Instrument Cluster Automatic EBS (Engine Braking System) w/E-Z Shift H/L/N/R/P 23.91:1 21.74:1 8.28:1 3.82:1 25x8-12 / 5 psi (34.5 KPa) 25x11-12 / 5 psi (34.
POLARIS PRODUCTS Part Number 2870791 2876244 2876245 2873602 2873603 2876144 2871653 2872276 2870465 2876251 2871323 2871534 2871312 2871322 2871423 2871460 2871515 2871551 2871329 2872073 2872348 Description Engine Lubricant Fogging Oil (12 oz. Aerosol) PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (.95 l) PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (3.8 l) Gearcase / Transmission Lubricants Premium AGL Synthetic Gearcase Lubricant (.95 l) Premium AGL Synthetic Gearcase Lube (3.
Drive Belt Wear/Burn Possible Cause Driving onto a pickup or tall trailer in high range Starting out going up a steep incline Driving at low RPM or ground speed (5-11 kmh) Insufficient warm-up at low ambient temperatures TROUBLESHOOTING Solution Use low range. Use low range or turn around using the K-turn (see page 54). Drive at a higher speed or use low range more frequently. Warm the engine at least 5 minutes.
TROUBLESHOOTING Engine Does Not Rotate Possible Cause Low battery voltage Loose battery connections Loose solenoid connections Solution Recharge the battery to 12.
TROUBLESHOOTING Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range Solution Replace with recommended fuel See your dealer Set gap to specs or replace plugs Engine Runs Irregularly, Stalls or Misfires Possible Cause Fouled or defective spark plug(s) Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Water present in fuel Low battery voltage Kinked or plugged fuel tank vent l
TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Water is present in fuel Old or non-recommended fuel Fouled or defective spark plug(s) Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Clogged air filter Reverse speed limiter malfunction Electronic throttle control malfunction Other mechanical failure Overheated engine Solution Refuel, cycle key to ON position three times for 5 sec
LIMITED WARRANTY WARRANTY Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a TWO YEAR LIMITED WARRANTY on all components of the Polaris Quadricycle 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 transferable to another consumer during the warranty period through a Polaris dealer.
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.
HOW TO OBTAIN WARRANTY SERVICE WARRANTY If your Quadricycle requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris Quadricycles. 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.
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.
MAINTENANCE LOG DATE KILOMETERS OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 129
