WARNING The engine exhaust from this product contains chemicals known to the State of California 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 1-800-3423764 for assistance.
The text is printed on 100% recycled with 40% post-consumer waste (PCW).
Pantone 426C WARNING Improper vehicle use can result in SEVERE INJURY or DEATH.
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) • RANGER® utility vehicles • Victory Motorcycles® We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today.
POLARIS, THE WAY OUT and SPORTSMAN are registered trademarks of Polaris Industries Inc. Copyright 2009 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 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Features and Controls . . . . . . . . . . . . . . . . . . . 26 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Emission Control Systems . . . . . . . . . . . . . . . 66 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 120 Specifications . . .
INTRODUCTION The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard. WARNING A WARNING indicates a hazardous situation which, if not avoided, may result in death or serious injury.
INTRODUCTION WARNING Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions. • Read this owner’s manual.
INTRODUCTION Vehicle Identification Numbers Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a Polaris key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost.
SAFETY Safety Training ATV safety training is a top priority for Polaris. Polaris strongly encourages you and any family members who will be riding the ATV to take a training course. If you purchased a new Polaris ATV in the United States, your dealer provided instruction to you about the authorized ATV RiderCoursesm that is available to you and your eligible family members. This training is included in the purchase price of your ATV.
SAFETY Safe Riding Gear Always wear appropriate clothing when riding an ATV. Wear protective clothing for comfort and to reduce the chance of injury. Helmet Eye Protection Long Sleeves Gloves Long Pants Boots Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.
SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean. Gloves Off-road style gloves with knuckle pads are the best for comfort and protection.
SAFETY Safety Warnings WARNING Failure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual. See the OPERATION section of the owner’s manual for proper operating procedures. Operating Without Instruction Operating this ATV without proper instruction increases the risk of an accident.
SAFETY Safety Warnings Handling Gasoline Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. • Always refuel with the engine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. • Do not overfill the tank. Do not fill the tank neck.
SAFETY Safety Warnings Protective Apparel Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a serious injuries in the event of an accident. Operator and passenger must always wear an approved helmet that fits properly and eye protection (goggles or face shield). Carrying a Passenger Do not carry a passenger until you have at least two hours of driving experience with this vehicle.
SAFETY Safety Warnings Operating on Pavement Operating an ATV on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the ATV and could result in loss of control and accident or overturn. Avoid operating the ATV on pavement. ATV tires are designed for off-road use. If it's unavoidable, travel slowly and avoid sudden turns or stops.
SAFETY Safety Warnings Physical Control of the ATV Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV. If a person's feet are not firmly planted on the footrests, they could come into contact with the wheels or other moving parts and lead to accident or injury. Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation.
SAFETY Safety Warnings Improper Hill Climbing Improper hill climbing could cause loss of control or overturn. Always follow proper procedures for climbing hills as described in the owner's manual. See page 54. Descending Hills Improperly Improperly descending a hill could cause loss of control or overturn. Always follow proper procedures for traveling down hills as described in the owner's manual. See page 58. Crossing Hillsides Driving on a sidehill is not recommended.
SAFETY Safety Warnings Stalling While Climbing a Hill Stalling, rolling backwards or improperly dismounting while climbing a hill could cause an overturn. • Always maintain a steady speed when climbing a hill. If all forward speed is lost: • Lean forward to keep body weight uphill. A passenger should also lean uphill. • Apply the single lever brakes. • Lock the parking brake when fully stopped. • Dismount on the uphill side of the vehicle, or on the left if the vehicle is pointing straight uphill.
SAFETY Safety Warnings Operating on Slippery Terrain Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or overturn. Do not operate on excessively rough, slippery or loose terrain until you've learned and practiced the skills necessary to control the ATV on such terrain. Always use extra caution on rough, slippery or loose terrain.
SAFETY Safety Warnings Improper Tire Maintenance Operating this ATV with improper tires or with improper or uneven tire pressure could cause loss of control or accident. Always use the size and type of tires specified for your ATV. Always maintain proper tire pressure as described in the owner's manual and on safety labels. Operating Over Obstacles Improperly operating over obstacles could cause loss of control or overturn. Before operating in a new area, check for obstacles.
SAFETY Safety Warnings Operating Through Deep Water Operating the ATV through deep or fastflowing water could cause the tires to float, causing loss of control or overturn. Avoid operating the ATV through deep or fast-flowing water. If it's unavoidable to enter water that exceeds the recommended maximum depth (see page 59): • Travel slowly. • Balance your weight carefully. • Avoid sudden movements. • Maintain a slow and steady forward motion.
SAFETY Safety Warnings Operating on Frozen Bodies of Water Operating on frozen bodies of water may result in serious injury or death if the ATV and/or riders fall through the ice. Never operate the ATV on a frozen body of water. Poor Visibility Operating the ATV in darkness or inclement weather could result in a collision or accident, especially if operating on a road or street. This ATV is not equipped with highway-approved lights. Operate this vehicle off-road only.
SAFETY Safety Warnings Operating a Damaged ATV Operating a damaged ATV can result in an accident. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems. Physical Skills Safe operation of this rider-active vehicle requires good judgement and physical skills.
SAFETY Safety Labels and Locations Warning decals have been placed on the ATV for your protection. Read and follow the instructions of the decals on the ATV carefully. If any of the decals depicted in this manual differ from the decals on your ATV, always read and follow the instructions of the decals on the ATV. If an informational or graphic label becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety labels are provided by Polaris at no charge.
SAFETY Safety Labels and Locations General Warning/Discretionary Warning WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR FOR DRIVER AND PASSENGER NEVER USE ON PUBLIC ROADS NEVER CARRY MORE THAN 1 PASSENGER NEVER USE WITH DRUGS OR ALCOHOL NEVER operate: • without proper ATV training or instruction • at speeds too fast for your skills or the conditions • on public roads - a collision can occur with another vehicle • with a passenger unless passen
SAFETY Safety Labels and Locations Passenger Safety Warning WARNING PASSENGER SAFETY To reduce the risk of SEVERE INJURY or DEATH NEVER CARRY MORE THAN ONE PASSENGER NEVER RIDE AFTER USING DRUGS OR ALCOHOL NEVER carry a passenger too small to firmly plant Passenger Safety feet on footrests and securely grasp hand holds.
SAFETY Safety Labels and Locations Rack Warning Rack Warning + + + Clutch Cover Warning Rack Warning 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 Warning WARNING • Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed. • Do not modify engine or clutch.
FEATURES AND CONTROLS Switches Headlight Switch Mode/Reverse Override Switch Engine Stop Switch Choke AWD Switch Main Key Switch Mode/Reverse Override Switch This vehicle is equipped with a reverse speed limiter system.To gain additional wheel speed while backing, depress the override switch. WARNING! Activating the override switch while the throttle is open can cause loss of control, which may result in serious injury or death. Always release the throttle before activating the override switch.
FEATURES AND CONTROLS Switches Engine Stop Switch Move the stop switch either left or right to the OFF position to stop the engine quickly. OFF RUN OFF The engine will not start or run when the switch is off. Both the main switch and the engine stop switch will shut off all electrical power to the vehicle, including lights. Main Key Switch Use the main key switch to start the engine. See page 47. AWD Switch Use the AWD switch to engage 4X4 or 2X4. See page 35.
FEATURES AND CONTROLS Throttle Lever WARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident. Never start or operate an ATV that has a sticking or improperly operating throttle. Always contact your dealer for service before operating the vehicle. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation.
FEATURES AND CONTROLS Brake 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 contact your dealer for service before operating the vehicle. Squeeze the brake lever toward the handlebar to apply the front and rear brakes. These brakes are hydraulically activated disc type brakes that are activated by only one lever.
FEATURES AND CONTROLS Master Cylinder/Brake Fluid WARNING An over-full master cylinder may cause brake drag or brake lock-up, which could result in an accident. Maintain brake fluid at the recommended level. Do not overfill. Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air.
FEATURES AND CONTROLS Parking Brake Locking the Parking Brake 1. Place the transmission in PARK. 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock forward to engage the lock. 4. Release the brake lever. 5. To release the parking brake lock, squeeze and release the brake lever. It will return to its unlocked position. WARNING! Operating the ATV while the parking brake is engaged could result in an accident or fire.
FEATURES AND CONTROLS Auxiliary Foot Brake WARNING Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death. Never back down a hill. Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward. The rear wheels may skid and slide sideways, causing loss of control and serious injury or death.
FEATURES AND CONTROLS Automatic Transmission Gear Selector Gear The transmission gear selector is Selector located on the right side of the vehicle. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park To shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear. NOTICE: Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage.
FEATURES AND CONTROLS Passenger Seat Always make sure the passenger Latch seat is installed and securely latched before operating with a passenger. Test the seat latch by attempting to pull the seat upward. If the lock-out is not working properly, do not allow a passenger to ride the vehicle. See your Polaris dealer for service. To remove the seat, pull the latch loop at the rear of the seat. Pull the seat upward to remove it from the vehicle.
FEATURES AND CONTROLS All Wheel Drive (AWD) System The All Wheel Drive system is controlled by the AWD switch. When the switch is on 2X4, the ATV is in two-wheel drive at all times. When the switch is on AWD, the ATV is in all wheel drive and the AWD indicator light in the instrument cluster will be AWD on. Switch When in AWD, the demand drive unit will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the demand drive unit will automatically disengage.
FEATURES AND CONTROLS Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from a sensor in the transmission. In addition to showing vehicle speed, the speedometer needle flashes when a warning condition exists. The instrument cluster measures distance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV's speed to approximately 7-9 mph (11-14 km/h). Refer to page 26 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. 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 ATV 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 26. The transmission cannot be in reverse when using this feature. Odometer Mode The odometer records the miles traveled by the ATV. Trip Meter Mode The trip meter records the miles traveled by the ATV on each trip if it's reset before each trip. To reset the trip meter, select the trip meter mode.
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. AWD Diagnostic Screen The gauge indicates whether or not current is flowing through the AWD coil (only on models with switchable AWD). 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.
OPERATION WARNING Failure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual. Break-In Period The break-in period for your new Polaris ATV is the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline.
OPERATION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 34. Always exercise extreme caution whenever handling gasoline. 2. Check the engine oil level on the dipstick. See page 72. Add oil if necessary to maintain the level between the safe and add marks. 3. Drive slowly at first. Select an open area that allows room to familiarize yourself with vehicle operation and handling. 4. Vary the throttle positions. Do not operate at sustained idle. 5.
OPERATION Pre-Ride Checklist Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident. Always inspect the ATV before each use to make sure it's in safe operating condition.
OPERATION Safe Operation Practices 1. Complete the recommended safety training before operating this vehicle. See page 7. 2. Do not allow anyone under 16 years of age to operate this vehicle. Do not allow anyone with cognitive or physical disabilities to operate this vehicle. 3. Engine exhaust fumes are poisonous. Never start the engine or let it run in an enclosed area. 4. Before operating, learn how to use the auxiliary brake for emergency situations (if service brakes become inoperable). 5.
OPERATION Know Your Riding Area/Tread Lightly Familiarize yourself with all laws and regulations concerning the operation of this off-road vehicle in your area. Respect the environment in which you ride. Find out where the designated riding areas are by contacting your Polaris dealer, a local riding club or local officials. Help keep our trails open for recreational vehicle use. As an off-road enthusiast, you represent the sport and can set a good example (or a poor example) for others to follow.
OPERATION Starting the Engine 1. Position the vehicle on a level surface outdoors or in a well-ventilated area. 2. Place the transmission in PARK. 3. Lock the parking brake. Tip: The starter interlock will prevent the engine from starting if the transmission is in gear and the brake is not engaged. 4. Turn the fuel valve on. 5. Sit on the vehicle. 6. Do not use the choke if starting a warm engine. Excessive use of the choke can cause the spark plug to become wet fouled. 7.
OPERATION Starting the Engine 11. Turn the ignition key past the ON position to engage the starter. Activate the starter for a maximum of five seconds, releasing the key when the engine starts. NOTICE: Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating the vehicle. 12. If the engine does not start, return the key to the OFF position and wait five seconds before attempting to start again.
OPERATION Driving Procedures 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Wear protective riding gear. See page 8. Perform the pre-ride inspection. See page 44. Place the transmission in PARK. Lock the parking brake. Mount the vehicle from the left side. Sit upright with both feet on the footrests and both hands on the handlebars. Start the engine and allow it to warm up. Shift the transmission into gear. Check your surroundings and determine your path of travel. Release the parking brake.
OPERATION Driving with a Passenger 1. Never allow anyone under 12 years of age to ride as a passenger on this 2-up ATV. Make sure any passenger is tall enough to comfortably and safely reach the grab handles and footrests. 2. Do not carry a passenger until you have at least two hours of driving experience with this vehicle. 3. Make sure the passenger is wearing appropriate riding gear, including an approved helmet with a rigid chin guard. See page 8. 4. Perform the pre-ride inspection. See page 44. 5.
OPERATION Driving with a Passenger 11. Ride to the ability of your passenger, instead of to your own ability. Avoid unexpected or aggressive maneuvers that could cause a passenger to fall from the vehicle. 12. Do not cross a hillside with a passenger on board. See page 55. 13. 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.
OPERATION Turning the Vehicle Your ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the outside wheel must travel a greater distance than the inside wheel when turning, and the inside tire must slip traction slightly. 1. Slow down. 2. Never turn quickly when carrying a passenger or cargo. 3. Steer in the direction of the turn. 4. Keep both feet on the footrests. 5.
OPERATION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Do not operate on excessively rough, slippery or loose terrain. 2. Slow down when entering slippery areas. 3. Engage AWD before wheels begin to lose traction. NOTICE: Severe damage to drive train may occur if the AWD is engaged while the wheels are spinning.
OPERATION Driving Uphill 15° Maximum Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn. Whenever traveling uphill, follow these precautions: 1. Drive straight uphill. 2. Avoid steep hills (15° maximum). 3. Always check the terrain carefully before ascending any hill. 4. Never climb hills with excessively slippery or loose surfaces. 5. Keep both feet on the footrests. 6. Shift body weight uphill.
OPERATION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary. If crossing a sidehill is unavoidable, follow these precautions: 1. Slow down. 2. Avoid crossing the side of a steep hill. 3. Do not cross a hillside with a passenger on board. Ask the passenger to dismount and walk across the hillside before remounting the vehicle. 4.
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. 8 ft. (2.
OPERATION Turning Around on a Hill (K-Turn) 1. Stop and lock the parking brake while keeping body weight uphill. 2. Leave the transmission in forward and shut off the engine. 3. If a passenger is on board, ask the passenger to dismount first, then the operator may dismount. Dismount on the uphill side of the vehicle, or on the left if the vehicle is pointing straight uphill. A passenger should not remount until the vehicle returns to firm, level ground. 4.
OPERATION Driving Downhill 15° Maximum When driving downhill, follow these precautions: 1. Avoid steep hills (15° maximum). 2. Always check the terrain carefully before descending a hill. 3. Always descend a hill with the transmission in forward gear. Do not descend a hill with the transmission in neutral. 4. Slow down. Never travel down a hill at high speed. 5. Drive straight downhill. Avoid traveling down a hill at an angle, which would cause the vehicle to lean sharply to one side. 6.
OPERATION Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests. Follow these procedures when operating through water: 1. Determine water depths and current before entering water. 2. Choose a crossing where both banks have Maximum Depth gradual inclines. 3. Avoid operating through deep or fast-flowing water. NOTICE: Major engine damage can result if the vehicle is not thoroughly inspected after operation in water.
OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches. 3. Travel slowly and use extra caution when operating on unfamiliar terrain. Not all obstacles are immediately visible. 4. Never attempt to operate over large obstacles, such as rocks or fallen trees. 5.
OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. Be aware that a passenger can obstruct your view. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles. 6. Never open the throttle suddenly. 7. Do not use the override switch unless additional wheel speed is required for vehicle movement.
OPERATION Parking on an Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Stop the engine. 2. Place the transmission in PARK. 3. Lock the parking brake. 4. Always block the rear wheels on the downhill side. 5. Turn the fuel valve off.
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, which can result in serious injury or death. Always follow these precautions when hauling cargo: Never carry cargo on the rear rack when operating the ATV in the 2-up mode with a passenger. REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO. NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle.
OPERATION Hauling Cargo Never exceed the weight capacities specified for your ATV on warning 2/3 labels and in the specifications sec1/3 tion of this manual. 1. Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as possible. 2. When operating over rough or hilly terrain, reduce speed and cargo weight to maintain stable driving conditions. 3. Do not obstruct the headlight beam with cargo. 4. Slow down. 5.
OPERATION Hauling Cargo Towing Loads Always attach a towed load to the hitch point. Remove the hitch from the ATV when not towing a trailer. If towing a load, reduce rear rack cargo weight by the amount of tongue weight. • The combination of rear rack cargo weight and tongue weight must not exceed the rear rack capacity. • The total load (operator, passenger, accessories, cargo and weight on hitch) must not exceed the maximum weight capacity of the vehicle.
EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USFS standard 5100-1c.
MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. Record maintenance and service in the Maintenance Log beginning on page 136.
MAINTENANCE Periodic Maintenance Chart WARNING Improperly performing the procedures marked with a Q could result in component failure and cause an accident, which may result in serious injury or death. Always have an authorized Polaris dealer perform these services. Maintenance Chart Key X Perform these operations more often for vehicles subjected to severe use. E Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.
MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Hours Calendar X Air filter, E main element Recoil housing (if applicable) X Brake pad wear Remarks (whichever comes first) Miles (Km) - Weekly - Inspect; replace as needed - Weekly - Drain water as needed, check often if operating in wet conditions 10 H Monthly 100 (160) Inspect periodically Q 20 H Monthly 200 (320) Check terminals; clean; test X Rear gearcase oil (if equipped) Battery 25 H Monthly 250 (400) Inspec
MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) Q Valve clearance 100 H 12 M 1000 (1600) Inspect; adjust Q Fuel system/filter 100 H 12 M 1000 (1600) Check for leaks at tank cap, lines, fuel valve, filter, pump, carburetor; replace lines every two years X Radiator (if applicable) 100 H 12 M 1000 (1600) Inspect; clean external surfaces X Cooling hoses (if applicable) 100 H 12 M 1000 (1600) Inspect for leaks X Engi
MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 67. Items not listed in the chart should be lubricated at the General Lubrication interval. 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 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. See page 126 for the part numbers of Polaris products. Premium 4 possesses unsurpassed film strength over the widest possible temperature range.
MAINTENANCE Engine Oil Oil Level Access the oil dipstick and fill tube from the left side of the ATV. Tip: A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase. If the oil level is over the full/safe mark, change the oil immediately. Dipstick Safe Range { 1. Position the vehicle on a level surface. 2. Start the engine. Allow it to idle for 20-30 seconds. Stop the engine. 3. Remove the dipstick.
MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 67. 1. Position the vehicle on a level surface. 2. Start the engine. Allow it to idle for two to three minutes. 3. Stop the engine. 4. Clean the area around the drain plug. 5. Place a drain pan under the oil Screen Fitting tank. Drain 6. Remove the drain plug. Allow Plug the oil to drain completely. CAUTION! Hot oil can cause burns to skin.
MAINTENANCE Engine Oil Oil and Filter Change 12. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter counter-clockwise to remove it. 13. Make sure the o-ring from the old filter is completely removed from the engine. Using a clean dry cloth, clean the filter sealing surface on the crankcase. 14. Lubricate the o-ring on the new filter with a film of fresh engine oil. Check to make sure the o-ring is in good condition. 15.
MAINTENANCE Engine Oil Oil and Filter Change Oil Pump Priming This priming procedure must be Tank performed whenever the oil hose 2" connection between the oil tank and (5 cm) pump inlet has been disconnected. 1. Clamp or pinch off the vent line approximately 2" (5 cm) from the oil tank, between the end of Clamp the oil tank vent fitting and the Pressure vent line's pressure relief slit. Relief Slit 2. Start the engine. Allow it to idle for 10-20 seconds. 3. Remove the vent line clamp.
MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 67. Maintain the oil level at the bottom of the fill plug hole threads. We recommend the use of Polaris Premium AGL Synthetic Gearcase Lubricant. See page 126 for the part numbers of Polaris products. The fill plug is located on the left side of the ATV, under the rear fender, behind the wheel.
MAINTENANCE Transmission Oil Transmission Oil Change 1. Remove the fill plug. 2. Place a drain pan under the gearcase. 3. Remove the drain plug. Allow the oil to drain completely. 4. Clean and reinstall the drain plug. Torque to 20-25 ft. lbs. Drain (27-34 Nm). Plug 5. Add 32 oz. (948 ml) of the recommended oil. 6. Reinstall the fill plug. Torque to 20-25 ft. lbs. (27-34 Nm). 7. Check for leaks. Dispose of used oil properly.
MAINTENANCE Front Gearcase (Demand Drive) Fluid Always check and change the demand drive fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 67. We recommend the use of Demand Drive Plus Fluid. Use of other fluids may result in improper operation of components. See page 126 for the part numbers of Polaris products. Maintain the fluid level at Fill the bottom of the fill hole Plug threads. See below for capacity.
MAINTENANCE Front Gearcase (Demand Drive) Fluid Fluid Level 1. Position the vehicle on a level surface. 2. Remove the fill plug. Check the fluid level. 3. Add the recommended demand drive fluid as needed to bring the level to the bottom of the fill hole threads. 4. Reinstall the fill plug. Torque to 8-10 ft. lbs. (11-14 Nm). Fluid Change 1. 2. 3. 4. 5. 6. Position the vehicle on a level surface. Remove the fill plug. Place a drain pan under the demand drive unit. Remove the drain plug.
MAINTENANCE Cooling System The engine coolant level is controlled, or maintained, by the recovery system. The recovery system components are the recovery bottle, the radiator filler neck, the radiator pressure cap and the connecting hose. As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the engine, past the pressure cap, and into the recovery bottle.
MAINTENANCE Cooling System Recovery Bottle Coolant The recovery bottle is located on the left side of the vehicle. 1. Remove the left side panel. See page 86. 2. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool). 3. Add coolant as needed.
MAINTENANCE Cooling System Radiator Coolant To ensure that the coolant maintains its ability to protect the engine, Polaris recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water. Replace the coolant any time the cooling system has been drained for maintenance or repair. If the recovery bottle has run dry, check the level in the radiator. Add coolant as needed. CAUTION! Escaping steam can cause burns.
MAINTENANCE Brakes Hand Brake The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. These brakes are selfadjusting. Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced. To ensure proper diaphragm operation, always fill the reservoir as needed whenever the cover is loosened or removed.
MAINTENANCE Toe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8" to 1/4" (3-6 mm) toe out. WARNING! Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized Polaris dealer. 1. Position the vehicle on a level surface. 2. Place the handlebars in a Stand straight-ahead position. 3.
MAINTENANCE Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Side Panel Removal 1. Remove the seat. 2. Grasp the rear of the side panel near the rear cab. With a firm motion, pull the panel outward to disengage the side panel from the grommet. Pull the panel downward and rearward to remove it. 3.
MAINTENANCE Tires 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. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use original equipment size and type when replacing tires. Refer to the specifications section beginning on page 124 for recommended tire type, size and pressure.
MAINTENANCE Tires Wheel Installation 1. Place the transmission in PARK. 2. Lock the parking brake. 3. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation. 4. Install the wheel nuts and finger-tighten them. 5. Lower the vehicle to the ground. 6. Torque the wheel nuts to specification. WARNING! Loose nuts could cause a tire to come off during operation, which could result in an accident or overturn.
MAINTENANCE Air Filter 1. Remove the seat. 2. Release the air box cover clips, and remove the air box cover. 3. Loosen the clamp and remove the filter. 4. Remove the fabric type pre-filter from the main filter. Wash the prefilter in soapy water, then rinse and let dry. 5. Reinstall the pre-filter over the main filter. Install a new main filter if needed. 6. Reinstall the filter into the air box and tighten the clamp. Do not over-tighten the clamp, as filter damage could occur. 7.
MAINTENANCE Breather Filter/Hose The breather filter is on the hose that runs between the engine and air box. 1. Remove the left side panel. See page 86. 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 Breather Filter arrow to check for clogging. Replace a damaged or clogged filter. 4. Check the hoses for cracks, deterioration, abrasion, or leaks. Replace as needed. 5.
MAINTENANCE Fuse Replacement Fuse Feature Supported 5A Speedometer 20A (Main Fuse) Ignition, Lighting 20A Accessories, 12V Power Receptacle If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Spare fuses are provided in a compartment on the top of the access door. 1. Open the front box cover and pull open the access door. 2. Remove the suspect fuse from the fuse panel. If the fuse is blown, install a new fuse with the same amperage. 3.
MAINTENANCE Lights Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean headlights frequently and replace burned out headlamps promptly. Always make sure lights are adjusted properly for best visibility. Headlight Lamp Replacement When servicing a halogen lamp, avoid touching the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp.
MAINTENANCE Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 25 ft. (7.6 m) 2" (5 cm) 1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. Place the transmission in PARK. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. 3. Start the engine.Turn the headlight switch to high beam. 4.
MAINTENANCE Lights Headlight Housing Replacement 1. Remove the two screws on the lower front corners of the headlight pod. 2. Lift the pod slightly while depressing the tabs at the rear of the pod. 3. Lift the pod cover and disconnect the speedometer harnesses from the speedometer. 4. Unplug the headlamp from the wiring harness. 5. Use a small screwdriver to remove the o-rings from the headlight mounting tabs. 6. Pull the headlight housing up to release it from the locking tabs. 7.
MAINTENANCE Lights Lower Headlamp Replacement 1. Turn the back of the headlight harness counter-clockwise and pull the harness assembly away from the headlight assembly. 2. Remove the headlamp and install the new headlamp. 3. Reinstall the harness assembly into the headlight assembly. 4. Turn the headlight harness clockwise to secure the headlamp. Harness Taillight/Brakelight Lamp Replacement 1. Remove the harness connector from the back of the light assembly. 2.
MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 124 for the recommended spark plug type and gap for your vehicle. Torque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Plug Condition Torque Specification New Spark Plug 9-11 ft. lbs. (12-15 Nm) Previously Installed Spark Plug 17-20 ft. lbs.
MAINTENANCE Spark Plugs Spark Plug Inspection Normal Spark Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. The tip should not be flaky and white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetion adjustments. Wet Fouled Spark Plug The wet fouled insulator tip is black.
MAINTENANCE Camber and Caster The camber and caster are non-adjustable. Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counter-clockwise to increase or decrease spring tension. Tip: Accessory springs are available through your Polaris dealer.
MAINTENANCE Handlebars The handlebars can be adjusted for rider preference. WARNING! Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in loss of control and serious injury or death. Follow the adjustment procedures exactly, or see your Polaris dealer for service. 1. Remove the upper headlight pod. 2. Loosen the four handlebar bolts. 3. Adjust the handlebar to the desired height.
MAINTENANCE Carburetor 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 (305 m) increase in elevation.
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. 3. Loosen the adjuster lock nut. 4. Rotate the boot to turn the adjuster until 1/16" to 1/8" (1.5-3 mm) of freeplay is achieved at the thumb lever. While adjusting freeplay, be sure to flip the throttle lever back and forth. Boot 5. Tighten the lock nut. 6.
MAINTENANCE Vehicle Immersion If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it's impossible to take your ATV to a dealer before starting it, follow the steps outlined below. 1. Move the ATV to dry land or at the very least, to water below the footrests. 2. Check the air box. If water is present, dry the air box and replace the filter with a new filter. 3. Turn the fuel valve off. 4.
MAINTENANCE Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Never run the engine in an enclosed area. Remove any combustible materials from the area. Wear eye protection and leather work gloves. Do not stand behind or in front of the vehicle while purging. Never go under the vehicle while it's inclined. The exhaust system can get extremely hot. Do not perform service on the spark arrestor while the system is hot.
MAINTENANCE 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.
MAINTENANCE PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the 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.
MAINTENANCE PVT System When To Use Low Range and High Range Condition Range to Use Operating at speeds less than 7 MPH (11 km/h) Low Towing heavy loads Low Operating in rough terrain (swamps, mountains, etc.) Low Operating at speeds greater than 7 MPH (11 km/h) High PVT Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating. 1. Position the vehicle on a level surface. 2. Remove the drain plug.
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. WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water.
MAINTENANCE Battery Battery Removal 1. 2. 3. 4. 5. 6. Remove the battery hold-down strap. Remove the battery cover. On conventional batteries, remove the battery vent tube. Disconnect the black (negative) battery cable first. Disconnect the red (positive) battery cable last. Lift the battery out of the ATV. Be careful not to tip a conventional battery sideways, which could spill electrolyte.
MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 111 before installing the battery. 1. Ensure that the battery is fully charged. 2. Place the battery in the battery holder. 3. With conventional batteries, install the battery vent tube (sealed batteries do not have a vent tube).
MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge. Tip: Power plug leads may need to be bent down so that the battery cover can be installed.
MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during charging. See page 108. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as needed to raise the specific gravity to 1.270 or greater. 3. Reinstall the battery. See page 109. Make sure the positive terminal is toward the front of the vehicle.
MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition before and 1-2 hours after the end of charging. Charge Time State of Charge Voltage Action (Using constant current charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None required 75%-100% 12.5-12.8 volts 50%-75% 25%-50% 12.0-12.5 volts 11.5-12.0 volts None, check at 3 mos.
MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components. NOTICE: High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap. Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle.
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.
MAINTENANCE Cleaning and Storage 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. 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 NOTICE: Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period. Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. See page 113. 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.
MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 67. • Demand drive unit (front gearcase) • 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. Support the front end of the machine so the engine is level or tilted slightly rearward. 2. Remove the spark plug.
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 67. Battery Storage See pages 110-111 for storage and charging procedures. Storage Area/Covers Set the tire pressure and safely support the ATV with the tires slightly off the ground. Be sure the storage area is well ventilated. Cover the vehicle with a genuine Polaris cover. Do not use plastic or coated materials.
MAINTENANCE Transporting the ATV Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place the transmission in PARK. 3. Lock the parking brake. 4. Secure the fuel cap and oil cap. 5. Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope. Do not attach tie straps to the front A-arm bolt pockets, racks or handlebars. 6. Remove the key to prevent loss during transporting.
TROUBLESHOOTING 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 (3-7 MPH) Insufficient warm-up at low ambient temperatures Solution Use low range during loading. Use low range or turn around using the K-turn (see page 56). Drive at a higher speed or use low range more frequently. See page 106. Warm the engine at least 5 minutes.
TROUBLESHOOTING Engine Doesn't Turn Over 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 Overuse of choke Water is present in 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 Incorrect fuel 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
SPECIFICATIONS SPORTSMAN Touring 500 HO Maximum Weight Capacity 705 lbs. (320 kg) (includes operator, passenger, cargo, accessories) Dry Weight 770 lbs. (349 kg) (base model) Front Rack/Storage Box Capacity 90 lbs. (41 kg) Rear Rack Capacity 180 lbs. (82 kg) Receiver Hitch Tongue Capacity 120 lbs. (55 kg) (Rear rack capacity and tongue weight not to exceed 180 lbs./92 kg) Hitch Towing Rating 1225 lbs. (555.7 kg) Unbraked Trailer Towing 1995 lbs. (905 kg) Capacity* Overall Length 86 in.
SPECIFICATIONS SPORTSMAN Touring 500 HO Driving System Type Front Suspension Rear Suspension Transmission Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Tires/Pressure, Front Tires/Pressure, Rear Brakes, Front Brakes, Rear Brake, Auxiliary Brake, Parking Headlight Taillights Brake Light Instrument Cluster Automatic PVT (Polaris Variable Transmission) MacPherson strut with 8.2" (21 cm) travel Progressive rate with 8.
POLARIS PRODUCTS Part Number 2870791 2871281 2871844 2873602 2873603 2877922 2877923 2870465 2871654 2872277 2871323 2871534 2871312 2871322 2871423 2871460 2871515 2871551 2871329 2872073 2872348 2871326 2870652 2872189 2871956 2859044 126 Description Engine Lubricant Fogging Oil (12 oz. Aerosol) Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt./.95 l) Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (gal./3.8 l) Gearcase / Transmission Lubricants Premium AGL Synthetic Gearcase Lubricant (qt./.
DECLARATION OF CONFORMITY Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A. Telephone 763-542-0500 We, Polaris Industries Inc., declare that the vehicles listed below conform to the essential health and safety requirements applicable to off-road all-terrain vehicles. APPLICABLE EUROPEAN DIRECTIVES 98/37/EC as amended (Machinery Directive) TEST / EVALUATION METHODS EN 1050 hazard analysis CD 77/311/EEC driver-perceived noise level CISPR 12:2001 EN 55012:2002 CAN/CSA-C108.
WARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty. This warranty begins on the date of purchase.
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.
WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES This warranty also excludes failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment, tension, adjustment or altitude compensation; failure due to snow, water, dirt or other foreign substance ingestion/contamination; improper maintenance; modified components; use of aftermarket components resulting in f
WARRANTY 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 Exported Vehicles How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen, to be kept and used outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. Notice If your vehicle is registered outside of the country where it was purchased, and you have not followed the procedure set out above, your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind.
WARRANTY U.S.A. EPA Emissions Limited Warranty This emissions limited warranty is in addition to the Polaris standard limited warranty for your vehicle. Polaris Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S. Environmental Protection Agency emission regulations.
WARRANTY U.S.A. EPA Emissions Limited Warranty The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of Polaris, repair or replacement of any defective materials, components or products. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
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 MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 137
INDEX A C Accessories . . . . . . . . . . . . . . . . . . 118 Air Filter . . . . . . . . . . . . . . . . . . . . . 89 All Wheel Drive System . . . . . . . . . 35 Auxiliary Foot Brake . . . . . . . . . . . . 84 AWD Switch . . . . . . . . . . . . . . . 27, 35 Cold Weather Operation . . . . . . . . . . 48 Consumer Product Safety . . . . . . . . . . 7 Coolant Bottle . . . . . . . . . . . . . . . . . . 82 Coolant, Radiator. . . . . . . . . . . . . . . . 83 Cooling System . . . . . . . . . . . . . .
INDEX F K Fluid, Brake . . . . . . . . . . . . . . . . . . . 30 Fluid, Demand Drive . . . . . . . . . 79-80 Fluid Change, Demand Drive . . . . . . 80 Fluid Level, Brake . . . . . . . . . . . 30, 32 Fluid Level, Demand Drive . . . . . . . 80 Foot Brake, Auxiliary . . . . . . . . . . . . 32 Footwell Removal. . . . . . . . . . . . . . . 86 Fuel Filter . . . . . . . . . . . . . . . . . . . . . 34 Fuel Recommendations. . . . . . . . . . . 34 Fuel Safety . . . . . . . . . . . . . . . . . . . . 11 Fuel Tank Cap.
INDEX P S Parking Brake . . . . . . . . . . . . . . . . . 31 Parking on an Incline . . . . . . . . . . . . 62 Passenger Seat . . . . . . . . . . . . . . . . . 34 Periodic Maintenance Chart . . . . 67-70 Polaris Product List . . . . . . . . . . . . 126 Polishing the Vehicle. . . . . . . . . . . 114 Pre-Ride Checklist . . . . . . . . . . . . . . 44 PVT Break-In. . . . . . . . . . . . . . . . . . 43 PVT Drying . . . . . . . . . . . . . . . . . . 106 PVT System . . . . . . . . . . . . . . .
INDEX S V Switches . . . . . . . . . . . . . . . . . . . 26-27 AWD Switch. . . . . . . . . . . . 27, 35 Engine Stop Switch. . . . . . . . . . 27 Headlight Switch. . . . . . . . . . . . 27 Main Key Switch . . . . . . . . . . . 27 Mode Switch . . . . . . . . . . . . . . . 26 Reverse Override Switch . . . . . 26 Vehicle Identification Numbers . . . . . 6 Vehicle Immersion . . . . . . . . . . . . . 102 VIN . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 T Taillight Lamp Replacement . . . . . .
