Polaris Offroad Vehicle 330 User Manual

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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 1-800-342-3764 for assistance.

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WELCOME

Thank you for purchasing a Polaris vehicle, and welcome to our

world-wide family of Polaris owners. We proudly produce an exciting

line of utility and recreational products.

S Snowmobiles

S All-terrain vehicles (ATVs)

S RANGER utility vehicles

S Victory motorcycles

We believe Polaris sets a standard of excellence for all utility and

recreational vehicles manufactured in the world today. Many years of

experience have gone into the engineering, design, and development of

your Polaris vehicle, making it the finest machine we’ve ever

produced.

For safe and enjoyable operation of your vehicle, be sure to follow the

instructions and recommendations in this owner’s manual. Your

manual contains instructions for minor maintenance, but information

about major repairs is outlined in the Polaris Service Manual and

should be performed only by a Factory Certified Master Service Dealer

(MSD) Technician.

Your Polaris dealer knows your vehicle best and is interested in your

total satisfaction. Be sure to return to your dealership for all of your

service needs during, and after, the warranty period.

We also take great pride in our complete line of apparel, parts and

accessories, available through our online store at

www.purepolaris.com. Have your accessories and clothing delivered

right to your door!

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based on the latest product information at the time of publication. Due to constant

improvements in the design and quality of production components, some minor

discrepancies may result between the actual vehicle and the information presented in this

publication. Depictions and/or procedures in this publication are intended for reference

use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or

reuse of the depictions and/or procedures contained within, whether whole or in part, is

expressly prohibited.

Printed in U.S.A.

2008 Trail Blazer 330 Owner’s Manual P/N 9921539

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TABLE OF CONTENTS

KNOW YOUR VEHICLE . . . . . . . . . . . . . . . . . . . . . 5

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

FEATURES AND CONTROLS . . . . . . . . . . . . . . . 31

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

EMISSION CONTROL SYSTEMS . . . . . . . . . . . . 59

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 104

POLARIS PRODUCTS . . . . . . . . . . . . . . . . . . . . 107

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . 108

WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

MAINTENANCE LOG . . . . . . . . . . . . . . . . . . . . . 116

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

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KNOW YOUR VEHICLE

As the operator of the vehicle, you are responsible for your personal

safety, the safety of others, 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.

Vehicle Identification Numbers

Record your ATV’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.

31XX

Vehicle Model Number:

Frame VIN (1):

Engine Serial Number (right front side of engine crankcase):

Key Number (2):

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SAFETY

Operator Safety

WARNING

Failure to follow the warnings contained in this manual can result

in serious 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 and understand your owner’s manual and all warnings

before operating a Polaris ATV.

Age Restrictions

This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited

for anyone under 16 years of age.

Safety Training

ATV safety training is a top priority for Polaris. When you purchased

your new ATV, your dealer instructed you on the authorized ATV

RiderCourse^smavailable to you and your eligible family members.

This training is included in the purchase price of your ATV. Polaris

strongly encourages you and your eligible family members who will be

riding the ATV to take the ATV RiderCourse^sm. You were also

provided with printed materials that explain safe operating procedures.

You should review this information on a regular basis.

If you purchased a used Polaris ATV, you can take the ATV

RiderCourse^smby calling ATV Enrollment Express at (800) 887-2887

or by visiting www.atvsafety.org. Purchasers of a used Polaris ATV

will be charged for this training.

A Polaris ATV is an off-road vehicle. Familiarize yourself with all

laws and regulations concerning the operation of the ATV in your area.

We strongly advise you to strictly follow the recommended

maintenance program outlined in your owner’s manual. This

preventive maintenance program is designed to ensure that all critical

components on your vehicle are thoroughly inspected at specific

intervals.

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SAFETY

Operator Safety

The following signal words and symbols appear throughout this

manual and on your ATV. Your safety is involved when these words

and symbols are used. Become familiar with their meanings before

reading the manual.

The safety alert symbol, on your vehicle or in this manual, alerts

you to the potential for personal injury.

WARNING

The safety alert warning indicates a potential hazard that may

result in serious injury or death.

CAUTION

The safety alert caution indicates a potential hazard that may

result in minor personal injury or damage to the vehicle.

CAUTION

A caution indicates a situation that may result in damage to the

vehicle.

NOTE:

A note will alert you to important information or instructions.

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SAFETY

Operator Safety

WARNING

Serious injury or death can result if you do not follow these

instructions and procedures, which are outlined in further detail

within your owner’s manual.

S Read this manual and all labels carefully, and follow the operating

procedures described.

S Never operate an ATV without proper instruction. Take a training

course. Purchasers of a new Polaris ATV and their eligible family

members are entitled to take the ATV RiderCourse^sm. Contact ATV

Enrollment Express at (800) 887-2887 or visit www.atvsafety.org for

information on enrollment in the ATV RiderCourse^sm.

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

S Never permit a guest to operate the ATV unless the guest has read

this manual and all product labels and has completed a certified safe-

ty training course.

S Always avoid operating an ATV on paved surfaces, including side-

walks, driveways, parking lots, and streets.

S Never operate an ATV on a public street, road or highway, including

a dirt or gravel road.

S Never operate an ATV without wearing an approved helmet that fits

properly. Always wear eye protection (goggles or face shield),

gloves, boots, a long-sleeved shirt or jacket, and long pants.

S Never consume alcohol or drugs before or while operating an ATV.

S Never operate at excessive speeds. Travel at speeds appropriate for

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

S Never attempt wheelies, jumps or other stunts.

S Always inspect your ATV before each use to make sure it’s in safe

operating condition. Always follow the inspection and maintenance

procedures and schedules outlined in your owner’s manual.

S Always keep both hands on the handlebars and both feet on the foot-

rests of the ATV during operation.

S Always travel slowly and use extra caution when operating on unfa-

miliar terrain. Be alert to changing terrain conditions.

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

S Always follow proper turning procedures as described in this manu-

al. Practice turning at low speeds before attempting to turn at faster

speeds. Do not turn at excessive speeds.

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SAFETY

Operator Safety

S Always have the ATV inspected by an authorized Polaris dealer if

it’s been involved in an accident.

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

Practice on smaller hills before attempting larger hills.

S Always follow proper procedures for climbing hills. Check the ter-

rain carefully before ascend a hill. Never climb hills with excessive-

ly slippery or loose surfaces. Shift your weight forward. Never open

the throttle suddenly or make sudden gear changes. Never go over

the top of a hill at high speed.

S Always follow proper procedures for going downhill and for braking

on hills. Check the terrain carefully before you start down a hill.

Shift your weight backward. Never go down a hill at high speed.

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

to lean sharply to one side. Travel straight down the hill when pos-

sible.

S Always follow proper procedures for crossing the side of a hill.

Avoid hills with excessively slippery or loose surfaces. Shift your

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

around on any hill until you’ve mastered (on level ground) the turn-

ing technique outlined in this manual. Avoid crossing the side of a

steep hill when possible.

S Always use proper procedures if you stall or roll backwards while

climbing a hill. To avoid stalling, maintain a steady speed when

climbing a hill. If you stall or roll backwards, follow the special pro-

cedure for braking described in this manual. Always dismount on the

uphill side, or to either side if the ATV is pointed straight uphill.

Turn the ATV around and remount following the procedure de-

scribed in this manual.

S Always check for obstacles before operating in a new area. Never

attempt to operate over large obstacles, such as rocks or fallen trees.

Always follow proper procedures when operating over obstacles as

described in this manual.

S Always be careful of skidding or sliding. On slippery surfaces like

ice, travel slowly and use extra caution to reduce the chance of skid-

ding or sliding out of control.

S Avoid operating the ATV through deep or fast-flowing water. If it’s

unavoidable, travel slowly, balance your weight carefully, avoid sud-

den movements, and maintain a slow and steady forward motion. Do

not make sudden turns or stops, and do not make sudden throttle

changes.

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SAFETY

Operator Safety

S Wet brakes may have reduced stopping ability. Test your brakes after

leaving water. If necessary, apply them lightly several times to allow

friction to dry out the pads.

S Always check for obstacles or people behind the ATV before operat-

ing in reverse. When it’s safe to proceed in reverse, move slowly and

avoid turning at sharp angles.

S Always use the size and type of tires specified for your ATV, and

always maintain proper tire pressure.

S Never modify an ATV through improper installation or use of acces-

sories.

S Never exceed the stated load capacity for your ATV. Cargo must be

properly distributed and securely attached. Reduce speed and follow

the instructions in this manual for carrying cargo or towing. Allow a

greater distance for braking.

S Always remove the ignition key when the vehicle is not in use to

prevent unauthorized use or accidental starting.

FOR MORE INFORMATION ABOUT ATV SAFETY, call the Con-

sumer Product Safety Commission at 1-800-638-2772, or visit

www.cpsc.gov, visit www.atvsafety.org, or call

Polaris at 1-800-342-3764.

Equipment Modifications

We are concerned for the safety of our customers and for the general

public. Therefore, we strongly recommend that consumers do not

install on a Polaris ATV any equipment that may increase the speed or

power of the vehicle, or make any other modifications to the vehicle

for these purposes. Any modifications to the original equipment of the

vehicle create a substantial safety hazard and increase the risk of bodily

injury.

The warranty on your Polaris ATV is terminated if any equipment has

been added to the vehicle, or if any modifications have been made to

the vehicle, that increase its speed or power.

NOTE: The addition of certain accessories, including (but not limited

to) mowers, blades, tires, sprayers, or large racks, may

change the handling characteristics of the vehicle. Use only

Polaris-approved accessories, and familiarize yourself with

their function and effect on the vehicle.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating this ATV without proper instruction.

WHAT CAN HAPPEN

The risk of an accident is greatly increased if the operator does

not know how to operate the ATV properly in different situations

and on different types of terrain.

HOW TO AVOID THE HAZARD

Beginning and inexperienced operators should complete the ATV

RiderCourse^smoffered by Polaris through the SVIA. They should

then regularly practice the skills learned in the course and the

operating techniques described in the Owner’s Manual.

For more information about the ATV RiderCourse^smcontact ATV

Enrollment Express at (800) 887-2887 or visit www.atvsafety.org.

WARNING

POTENTIAL HAZARD

Failure to follow the age recommendations for this ATV.

WHAT CAN HAPPEN

Severe injury and/or death could occur if a child under the

minimum age recommendation operates an ATV.

Even though a child may be within the recommended age group

for operating some ATVs, he/she may not have the skills,

abilities, or judgment needed to operate an ATV safely and could

be susceptible to accident or injury.

HOW TO AVOID THE HAZARD

No one under the age of 16 should operate a Polaris ATV.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Carrying a passenger on an

ATV.

WHAT CAN HAPPEN

Carrying a passenger

greatly reduces the

operator’s ability to balance

and control the ATV, which

could cause an accident

and injury to the

operator and/or passenger.

HOW TO AVOID THE HAZARD

Never carry a passenger. The purpose of the long seat is to

allow the operator to shift position as needed during operation. It

is not intended for carrying passengers.

WARNING

POTENTIAL HAZARD

Operating an ATV

on paved

surfaces, including

sidewalks, paths,

parking lots, and

driveways.

WHAT CAN HAPPEN

ATV tires are designed for

off-road use. Operating on

paved surfaces may

seriously affect the handling and

control of the ATV and could result in loss of control, accident,

and/or injury.

HOW TO AVOID THE HAZARD

Avoid operating the ATV on pavement. If it’s unavoidable, travel

slowly and avoid sudden turns or stops.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating this ATV on

public streets, roads or

highways.

WHAT CAN HAPPEN

The ATV could collide

with another vehicle.

HOW TO AVOID THE HAZARD

Never operate the ATV on any

public street, road or highway,

including dirt and gravel roads. In many states

it’s illegal to operate ATVs on public streets, roads and highways.

WARNING

POTENTIAL HAZARD

Operating this ATV without

wearing an approved

helmet, eye protection and

protective clothing.

WHAT CAN HAPPEN

Operating an ATV without

an approved helmet

increases the risk of a

severe head injury or

death in the event of an

accident.

Operating without eye protection could result in an accident and

could increase the chance of a severe injury in the event of an

accident.

HOW TO AVOID THE HAZARD

Always wear an approved helmet that fits properly.

Always wear eye protection (goggles or face shield), gloves,

boots, long-sleeved shirt or jacket, and long pants.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating the ATV after consuming

alcohol or drugs.

WHAT CAN HAPPEN

Consumption of alcohol and/or drugs

could seriously affect operator

judgment. Reaction time may be slower

and operator balance and perception

could be affected.

Consuming alcohol and/or drugs before

or while operating an ATV could result in

an accident causing severe injury or death.

HOW TO AVOID THE HAZARD

Never consume alcohol or drugs before or while operating an

ATV.

WARNING

POTENTIAL HAZARD

Operating the ATV at excessive speeds.

WHAT CAN HAPPEN

Excessive speed increases the operator’s chance of losing

control of the ATV, which can result in an accident.

HOW TO AVOID THE HAZARD

Always operate the ATV at a speed that’s proper for the terrain,

visibility and operating conditions, and your experience.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Attempting wheelies, jumps

and other stunts.

WHAT CAN HAPPEN

Attempting stunts increases

the chance of an accident,

including an overturn.

HOW TO AVOID THE

HAZARD

Never attempt wheelies,

jumps, or other stunts. Avoid

exhibition driving.

WARNING

POTENTIAL HAZARD

Failure to inspect the ATV before operating.

Failure to properly maintain the ATV.

WHAT CAN HAPPEN

Poor maintenance increases the possibility of an accident or

equipment damage.

HOW TO AVOID THE HAZARD

Always inspect your ATV before each use to make sure it’s in

safe operating condition.

Always follow the inspection and maintenance procedures and

schedules described in the owner’s manual.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Removing hands from the handlebars or feet from the footrests

during operation.

WHAT CAN HAPPEN

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 the operator’s foot is not firmly planted on the footrest, it could

come into contact with the rear wheels and lead to accident or

injury.

HOW TO AVOID THE HAZARD

Always keep both hands on the handlebars and both feet on the

footrests of the ATV during operation.

WARNING

POTENTIAL HAZARD

Failure to use extra

caution when operating

the ATV on unfamiliar

terrain.

WHAT CAN HAPPEN

Unfamiliar terrain may

contain hidden rocks,

bumps, or holes that could

cause loss of control or

overturn.

HOW TO AVOID THE HAZARD

Travel slowly and use extra caution when operating on unfamiliar

terrain. Always be alert to changing terrain conditions.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Failure to use extra

caution when operating on

excessively rough,

slippery or loose terrain.

WHAT CAN HAPPEN

Operating on excessively

rough, slippery or loose

terrain could cause loss of

traction or loss of control,

which could result in an

accident or overturn.

HOW TO AVOID THE HAZARD

Do not operate on excessively rough, slippery or loose terrain

until you’ve learned and practiced the skills necessary to control

the ATV on such terrain.

Always use extra caution on rough, slippery or loose terrain.

WARNING

POTENTIAL HAZARD

Turning improperly.

WHAT CAN HAPPEN

Improper turns could cause loss of control and lead to a collision

or overturn.

HOW TO AVOID THE HAZARD

Always follow proper procedures for turning as described in the

owner’s manual.

Practice turning at slow speeds before attempting to turn at faster

speeds.

Never turn at excessive speed.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating on excessively steep hills.

WHAT CAN HAPPEN

The vehicle may overturn.

HOW TO AVOID THE HAZARD

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

Never operate the ATV on hills steeper than 25_.

Practice on smaller hills before attempting large hills.

WARNING

POTENTIAL HAZARD

Climbing hills improperly.

WHAT CAN HAPPEN

Improper hill climbing could

cause loss of control or

overturn.

HOW TO AVOID THE

HAZARD

Always follow proper

procedures for climbing

hills as described in the

owner’s manual.

Always check the terrain

carefully before ascending

any hill.

Never operate the ATV on hills steeper than 25_.

Never climb hills with excessively slippery or loose surfaces.

Shift your weight forward.

Never open the throttle suddenly while traveling uphill. The ATV

could flip over backwards.

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

sharp drop, or another vehicle or person could be on the other

side of the hill.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Traveling downhill

improperly.

WHAT CAN HAPPEN

Improperly descending a hill

could cause loss of control

or overturn.

HOW TO AVOID THE

HAZARD

Always follow proper

procedures for traveling

down hills as described in

the owner’s manual. NOTE:

A special technique is

required when braking while

traveling downhill. See page 52.

Always check the terrain carefully before descending a hill.

Shift your weight backward.

Never travel down a hill at high speed.

Avoid traveling down a hill at an angle, which would cause the

vehicle to lean sharply to one side. Travel straight down the hill

when possible.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Improperly crossing hills and

turning on hills.

WHAT CAN HAPPEN

Improperly crossing or

turning as hills could cause

loss of control or overturn.

HOW TO AVOID THE

HAZARD

Never attempt to turn the

ATV around on any hill until

you’ve mastered the turning

technique (on level ground)

as described in the owner’s

manual. See page 54. Use

extra caution when turning

on any hill.

Avoid crossing the side of a steep hill.

When crossing the side of a hill:

Always follow proper procedures as described in the owner’s

manual.

Avoid hills with excessively slippery or loose surfaces.

Shift your weight to the uphill side of the ATV.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Stalling, rolling backwards

or improperly dismounting

while climbing a hill.

WHAT CAN HAPPEN

The vehicle could overturn.

HOW TO AVOID THE

HAZARD

Maintain steady speed

when climbing a hill.

If all forward speed is lost:

Keep your weight uphill.

Apply the single lever brake gradually.

When fully stopped, apply the auxiliary rear brake as well, then

lock the parking brake.

If the ATV begins rolling backwards:

Keep weight uphill.

Never apply engine power.

Never apply the auxiliary rear brake while rolling backwards.

Apply the single-lever brake gradually.

When fully stopped, apply the auxiliary rear brake as well, and

then lock the parking brake.

Dismount on uphill side, or to either side if ATV is pointed straight

uphill.

Turn the ATV around and remount, following the procedure

described in the owner’s manual. See page 54.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Improperly operating over obstacles.

WHAT CAN HAPPEN

Operating over obstacles could cause loss of control or overturn.

HOW TO AVOID THE HAZARD

Before operating in a new area, check for obstacles.

Avoid operating over large obstacles such as rocks and fallen

trees when possible. If unavoidable, use extreme caution and

always follow proper procedures as outlined in the owner’s

manual.

WARNING

POTENTIAL HAZARD

Skidding or sliding.

WHAT CAN HAPPEN

Skidding or sliding can cause loss of control.

If the tires regain traction unexpectedly, the ATV could overturn.

HOW TO AVOID THE HAZARD

On slippery surfaces such as ice, travel slowly and use extra

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

WARNING

POTENTIAL HAZARD

Improperly operating in reverse.

WHAT CAN HAPPEN

The ATV could collide with an obstacle or person, resulting in

severe injury.

HOW TO AVOID THE HAZARD

Before shifting into reverse gear, always check for obstacles or

people behind the ATV. When it’s safe to proceed, back slowly.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating the ATV through deep or fast-flowing water.

WHAT CAN HAPPEN

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

could lead to an accident or overturn.

HOW TO AVOID THE HAZARD

Avoid operating the ATV through deep or fast-flowing water. If it’s

unavoidable to enter water that exceeds the recommended

maximum depth (see page 55), travel slowly, balance your weight

carefully, avoid sudden movements, and maintain a slow and

steady forward motion. Do not make sudden turns or stops, and

do not make sudden throttle changes.

Wet brakes may have reduced stopping ability. Always test the

brakes after leaving water. If necessary, apply them several

times to let friction dry out the pads.

WARNING

POTENTIAL HAZARD

Operating this ATV with improper tires, or with improper or

uneven tire pressure.

WHAT CAN HAPPEN

Use of improper tires, or operation of the ATV with improper or

uneven tire pressure, could cause loss of control or accident.

HOW TO AVOID THE HAZARD

Always use the size and type of tires specified for the ATV.

Always maintain proper tire pressure as specified.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating the ATV with improper modifications.

WHAT CAN HAPPEN

Improper installation of accessories or modification of the ATV

may cause changes in handling which could lead to an accident.

HOW TO AVOID THE HAZARD

Never modify the ATV through improper installation or use of

accessories. All parts and accessories added to the vehicle must

be genuine Polaris Industries Inc. or equivalent components

designed for use on this ATV and should be installed and used

according to approved instructions. See your authorized Polaris

ATV dealer for more information.

WARNING

POTENTIAL HAZARD

Overloading the ATV or carrying/towing cargo improperly.

WHAT CAN HAPPEN

Overloading and towing can cause changes in vehicle handling,

which could lead to loss of control or an accident.

HOW TO AVOID THE HAZARD

Never exceed the stated load capacity for this ATV.

Cargo should be properly distributed and securely attached.

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

greater distance for braking.

Always follow the instructions in the owner’s manual for carrying

cargo or pulling a trailer. See page 46.

WARNING

POTENTIAL HAZARD

Operating on frozen bodies of water.

WHAT CAN HAPPEN

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

fall through the ice.

HOW TO AVOID THE HAZARD

Never operate the ATV on a frozen body of water.

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SAFETY

Operator Safety

WARNING

Leaving the keys in the ignition can lead to unauthorized use of

the vehicle resulting in serious injury or death. Always remove

the ignition key when the vehicle is not in use.

WARNING

After any overturn or accident, have a qualified service dealer

inspect the entire vehicle for possible damage, including (but not

limited to) brakes, throttle and steering systems.

WARNING

Safe operation of this rider-active vehicle requires good

judgement and physical skills. Persons with cognitive or physical

disabilities who operate this vehicle have an increased risk of

overturn and loss of control, which could result in severe injury or

death.

CAUTION

Exhaust system components are very hot during and after use of

the vehicle. Hot components can cause serious burns and fire.

Do not touch hot exhaust system components. Always keep

combustible materials away from the exhaust system. Use

caution when traveling through tall grass, especially dry grass.

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SAFETY

Fuel Safety

WARNING

Gasoline is highly flammable and explosive under certain

conditions.

S Always exercise extreme caution whenever handling gasoline.

S Always refuel with the engine stopped, and outdoors or in a well

ventilated area.

S Do not smoke or allow open flames or sparks in or near the

area where refueling is performed or where gasoline is stored.

S Do not overfill the tank. Do not fill the tank neck.

S If gasoline spills on your skin or clothing, immediately wash it off

with soap and water and change clothing.

S Never start the engine or let it run in an enclosed area.

Engine exhaust fumes are poisonous and can cause loss of

consciousness or death in a short time.

S Turn the fuel valve off whenever the ATV is stored or parked.

WARNING

The engine exhaust from this product contains chemicals known

to cause cancer, birth defects or other reproductive harm.

Operate this vehicle only outdoors or in well-ventilated areas.

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SAFETY

Safety Decals 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 any 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.

Discretionary Warning (1)

WARNING

S Never operate this vehicle on

HILLS steeper than 25 degrees

25°. To prevent flipover on

hilly terrain, when going up or

down, use throttle and brakes

gradually.

S REVERSE operation can be

dangerous, even at low speeds.

Steering becomes difficult. To

prevent flipover, avoid sudden

braking or sharp turns.

S Use OVERRIDE for reverse

speed limiter with caution. To

prevent loss of control, never activate

override button with open throttle.

S PARKING BRAKE may relax when used

for more than 5 minutes. When parking on grades, leave shift in forward.

Clutch Cover Warning (2)

WARNING

NO STEP

S Moving parts hazard under belt-clutch guard. To prevent serious injury, do

not operate vehicle with guard removed.

S Do not modify engine or clutch. Doing so can cause part failure, possible im-

balance, and excessive engine RPM, which can result in serious injury or

death.

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SAFETY

Safety Decals and Locations

General Warning (3)

WARNING

Improper ATV use can result in

SEVERE INJURY or DEATH

ALWAYS USE AN APPROVED

HELMET AND PROTECTIVE GEAR

NEVER USE ON PUBLIC ROADS

NEVER CARRY PASSENGERS

NEVER USE WITH DRUGS OR

ALCOHOL

NEVER operate:

S without proper training or instruction

S at speeds too fast for your skills or the

conditions

S on public roads -- a collision can occur with

another vehicle

S with a passenger -- passengers affect balance and steering and increase risk

of losing control

ALWAYS:

S use proper riding techniques to avoid vehicle overturns on hills and rough

terrain and in turns

S avoid paved surfaces -- pavement may seriously affect handling and control

LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS

AND WARNINGS. IF OWNER’S MANUAL IS MISSING, CONTACT A POLARIS

DEALER FOR A REPLACEMENT.

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SAFETY

Safety Decals and Locations

No Passenger Warning (4)

WARNING

NEVER ride as a passenger.

Passengers can cause a

loss of control, resulting in

SEVERE INJURY or

DEATH.

Age 16 Warning (5)

WARNING

Operating this ATV if you

are under the age of 16

increases your chance of

severe injury or death. NEVER

operate this ATV if you are under age 16.

Tire Pressure/Load Warning (6)

WARNING

IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control

resulting in SEVERE INJURY OR DEATH.

TIRE PRESSURE IN PSI (KPa): FRONT 4 (27.6) REAR 3 (20.7)

MAXIMUM WEIGHT CAPACITY 305 LBS. (138 KG).

Reduce speed and allow greater distance for braking when carrying cargo.

Overloading or carrying tall, off-center, or unsecured loads will increase your

risk of losing control. Loads should be centered, carried as low as possible, and

firmly secured to the racks. With dual racks, load distribution 1/3 front 2/3 rear is

best. For stability on rough or hilly terrain, reduce speed and cargo. Do not

block headlight. Be careful if load extends over the side of the rack.

Read Owner’s Manual for more detailed loading information.

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SAFETY

Safe Riding Gear

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

special protective clothing for comfort and to reduce the chance of

injury.

1. Helmet

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.

Approved helmets in Europe, Asia and

Oceania bear the ECE 22.05 label.

The ECE mark consists of

a circle surrounding the

letter E, followed by the

distinguishing number of

the country which has

granted approval. The

approval number and serial

number will also be

051039

0006.031

displayed on the label.

2. 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.

3. Gloves

Off-road style gloves with knuckle pads are the best for comfort and

protection.

4. Boots

The best footwear is a pair of sturdy over-the-calf boots with low heels.

5. Clothing

Always wear long sleeves and long pants to protect arms and legs.

Riding pants with kneepads and a jersey with shoulder pads provide

the best protection.

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FEATURES AND CONTROLS

Electrical Switches

WARNING

Activating the override switch while the throttle is open can cause

loss of control, resulting in severe injury or death. Do not activate

the override switch while the throttle is open.

Override Switch (1) (Reverse Speed Limiter) -

OFF RUN OFF

This vehicle is equipped with a reverse speed

limiter system. To gain additional power while

backing, depress the override switch.

Main Switch (2) - To start the engine, slide the stop

switch to the center RUN position and turn the main key switch

clockwise past the ON position. Release the key when the engine starts.

NOTE: Turn off the main switch to end all electrical power to the

vehicle, including the lights.

WARNING

Leaving the keys in the ignition can lead to unauthorized use of

the vehicle resulting in serious injury or death. Always remove

the ignition key when the vehicle is not in use.

Engine Stop Switch (3) - The engine will not start or run when the

switch is in its OFF position. Its purpose is to provide the operator

with a quick means of engine shutdown in case of an emergency. To

stop the engine, slide the stop switch either right or left to the OFF

position.

NOTE: Turning off the engine stop switch will shut off all electrical

power to the vehicle, including the lights.

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FEATURES AND CONTROLS

Light Switches

WARNING

Operating the ATV on streets or roads, especially in darkness,

could result in an accident and serious injury or death.

Your ATV is not equipped with highway-approved lights. It’s

designed for and must be used for off-road use only. Use caution

and drive at reduced speeds in conditions of reduced visibility

such as fog, rain and darkness.

Use the light switch (1) to turn the

lights on and off.

NOTE: The lights won’t work unless

the key is in the ON position

and the shut-off switch is in

the RUN position.

Indicator Lights

With the engine running, verify the function of all indicator lights each

time the ATV is used.

NOTE: The taillight is on whenever the main switch (key) is on. Turn

the key off to prevent battery drain.

1. Transmission Neutral Indicator

2. Transmission Reverse Indicator

3. High Temp Warning (displays if engine overheats)

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FEATURES AND CONTROLS

Throttle Lever

WARNING

Do not start or operate an ATV with sticking or improperly

operating throttle controls, which could cause an accident and

lead to severe injury or death.

Always contact your dealer for service repairs if throttle problems

arise.

Failure to check or maintain proper operation of the throttle

system can result in an accident if the throttle lever sticks during

operation.

Always check the lever for free movement and return before

starting the engine. Also check occasionally during operation.

Engine speed and vehicle movement

are controlled by pressing the

throttle lever. The throttle lever (1)

is spring loaded. Engine speed

returns to idle when the lever is

released.

This ATV is equipped with Polaris

Electronic Throttle Control (ETC),

which is designed to reduce the risk of a frozen or stuck throttle. If the

throttle cable should stick in an open position when the operator

releases the throttle lever, the engine will stop, and power to the rear

wheels will cease.

WARNING

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

event of a throttle system malfunction and is provided for your

safety. Do not attempt to modify the ETC system or replace it

with any after market throttle mechanisms.

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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.

The front and rear brakes are

applied by squeezing the brake

lever (1) toward the handlebar.

The front and rear brakes are

hydraulically activated disc type

brakes that are activated by only

one lever.

Always test brake lever travel and

master cylinder fluid level before

riding. When squeezed, the lever

should feel firm. Any sponginess would indicate a possible fluid leak

or low master cylinder fluid level, which must be corrected before

riding. Contact your dealer for proper diagnosis and repairs.

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FEATURES AND CONTROLS

Brakes

Check the brake fluid level in the

master cylinder before each use of

the ATV. The master cylinder (1) is

located on the left handlebar.

The fluid level can be seen through

an indicator window (2) on the top

of the master cylinder. This “eye”

will appear dark when the fluid level

is full. When fluid needs to be

added, the eye will be clear.

WARNING

An over-full master cylinder may cause brake drag or brake

lock-up, which could result in serious injury or death. Maintain

brake fluid at the recommended level. Do not overfill.

NOTE: When checking the fluid level, the ATV must be on level

ground with the handlebars straight. If the fluid level is low

add DOT 4 brake fluid only. DO NOT OVERFILL. See page

107 for the part numbers of Polaris products.

WARNING

Never store or use a partial bottle of brake fluid. Brake fluid is

hygroscopic, meaning it rapidly absorbs moisture from the air.

The moisture causes the boiling temperature of the brake fluid to

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

accident or severe injury. After opening a bottle of brake fluid,

always discard any unused portion.

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FEATURES AND CONTROLS

Parking Brake

WARNING

Operating the ATV while the parking brake is engaged could

result in an accident and serious injury or death. Always check to

be sure the parking brake is disengaged before operating.

Setting the Parking Brake

1. Squeeze and release the brake lever two or

three times, then squeeze and hold.

2. Push the park brake lock (1)

forward to engage the brake.

Release the brake lever.

3. To release the parking brake lock,

squeeze and release the brake

lever. It will return to its unlocked

position.

Important Safeguards

S The parking brake may relax if left on for a long period of time. Al-

ways block the wheels to prevent rolling.

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

it parked on a hill. Another option is to park the ATV in a sidehill

position.

S Never depend on the parking brake alone if the ATV is parked on a

hill. Always block the wheels to prevent rolling.

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FEATURES AND CONTROLS

Auxiliary Brake

WARNING

Aggressively applying the rear brake when backing downhill may

cause rear tipover, which could result in serious injury or death.

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.

The auxiliary foot brake (1), is

located on the inside of the right

floorboard and is operated by the

right foot. The auxiliary brake

serves as a backup to the main

brake system if the main system

becomes inoperative.

If the rear wheels slide while

using the auxiliary brake, reduce

brake pedal pressure to brake the

rear wheels without skidding.

Check the brake fluid level frequently for the auxiliary brake system.

The reservoir is located under the seat or near the foot brake. Maintain

the fluid level between the maximum and minimum marks.

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FEATURES AND CONTROLS

Choke

The choke assists in starting a cold engine. Refer to the engine starting

procedure on page 43 for correct choke and throttle settings during

starting.

Fuel Valve

RES

The fuel valve (1) is located on the left side of

the vehicle, below the fender. It has three

positions:

OFF

OFF: For vehicle storage and when transporting.

ON: For normal operation.

RES: For reserve supply if main

supply is exhausted.

NOTE: There’s about a 7 to 10 mile

(11.2 to 16 km) range on

reserve gas. Always refill the

gas tank as soon as possible

after using the reserve supply.

Always return the valve to the ON

position after refueling.

Fuel Tank

Remove the fuel tank cap (2) to add fuel to

the fuel tank. Use either leaded or

unleaded gasoline with a minimum pump

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

not use E--85 fuel.

Refer to the specifications section at the

rear of this manual for tank capacity.

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.

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FEATURES AND CONTROLS

Automatic Transmission Gear Selector

The transmission gear selector (1)

is located on the right side of the

vehicle.

F: Forward

N: Neutral

R: Reverse

CAUTION

Shifting gears with the engine speed above idle or while the

vehicle is moving could cause transmission damage.

To change gears, stop the vehicle, and with the engine idling,

move the lever to the desired gear.

Whenever the ATV is left unattended, always place the transmission in

gear and lock the parking brake.

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FEATURES AND CONTROLS

Recoil Starter

If the battery has been drained or

damaged and cannot start the

engine, use of the recoil starter (1)

will allow vehicle operation until

repairs can be made. The recoil

starter is located on the right side of

the machine.

Polaris 4-cycle engines are

equipped with automatic

decompressors. This makes recoil

starting possible by reducing the amount of compression during

starting. The decompressor senses when the engine is spinning fast

enough to start and restores compression when running.

1. Position the vehicle on a level surface and lock the parking brake

(see page 36).

2. Shift the transmission into neutral.

3. Make sure the engine stop switch is set to RUN and the main key

switch is in the ON position.

NOTE: If the engine is cold, use the choke as outlined on page 43.

4. Grasp the recoil starter rope handle (2) firmly and pull slowly so

you can feel the engine strokes.

NOTE: Every other stroke will be a “compression stroke” and will

make the rope harder to pull. When a compression stroke is

found, continue pulling the rope just until the engine rolls past

the stroke, then stop pulling immediately.

5. Allow the recoil rope to rewind into the recoil assembly, then pull

the rope abruptly and forcefully to start the engine.

6. Repeat steps 4-5 if necessary.

CAUTION

Extending the recoil starter rope until it stops can cause damage

to the recoil assembly. Do not extend the starter rope so far that

it stops.

If the starter rope handle is not seated properly, water may enter

the recoil housing and damage components. Make sure the

handle is fully seated on the recoil housing, especially when

traveling in wet areas.

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OPERATION

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.

No single action on your part is as important as 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.

CAUTION

Excessive heat build-up during the first three hours of operation

will damage close-fitted engine parts and drive components. Do

not operate at full throttle or high speeds during the first three

hours of use.

Engine and Drivetrain Break-in

1. Fill the fuel tank with gasoline (see page 38).

2. Check the oil level (see page 66). Add the recommended oil as

needed.

3. Drive slowly at first. Select an open area that allows room to

familiarize yourself with vehicle operation and handling.

4. Vary throttle positions. Do not operate at sustained idle.

5. Perform regular checks on fluid levels, controls and areas outlined

on the daily pre-ride inspection checklist. See page 42.

6. Pull only light loads.

7. During the break-in period, change both the oil and the filter at 20

hours or one month, whichever comes first.

PVT Break-in (Clutches/Belt)

A proper break-in of the clutches and drive belt will ensure a longer

life and better performance. Break in the clutches and belt by

operating at slower speeds during the break-in period as recommended.

Pull only light loads. Avoid aggressive acceleration and high speed

operation during the break-in period.

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OPERATION

Pre-Ride Inspection

WARNING

If a proper inspection is not done before each use, severe injury

or death could result. Always inspect the vehicle before each use

to ensure it’s in proper operating condition.

Pre-Ride Checklist

Item

Remarks

See

Page

Brake system / lever travel

Brake fluid

Ensure proper operation

Ensure proper level

34, 71

Auxiliary brake

Front suspension

Rear suspension

Steering

Ensure proper operation

Inspect, lubricate if necessary

Ensure free operation

Tires

Inspect condition and pressure

Inspect, ensure fastener tightness

Wheels / fasteners

Frame nuts, bolts, fasteners Inspect, ensure tightness

Fuel and oil

Ensure proper levels

Ensure proper level

Coolant level (if applicable)

Coolant hoses (if applicable) Inspect for leaks

Throttle

Ensure proper operation

33, 73

31, 32

Indicator lights / switches

Engine stop switch

Drive chain

Ensure operation

Ensure proper operation

Check condition / slack, lubricate as

needed

79, 80

Air filter, pre-filter

Air box sediment tube

Headlamp

Inspect, clean

Drain deposits whenever visible

Check operation, apply Polaris dielec-

tric grease when lamp is replaced

Brake light / tail lamp

Riding gear

Check operation, apply Polaris dielec-

tric grease when lamp is replaced

Wear helmet, goggles, protective

clothing

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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.

1. Position the vehicle on a level

surface.

2. Place the transmission in

neutral.

3. Lock the parking brake.

NOTE: 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.

NOTE: Do not use the choke if starting a warm engine. Excessive

use of the choke can cause the spark plug to become wet

fouled.

6. If the engine is cold, pull the choke knob out until it stops (1).

NOTE: The variable choke is fully on when the knob is pulled

completely out. The choke is off when the knob is pushed

completely in. The choke can be adjusted gradually,

depending on how much choke is needed for starting. Be

sure the choke is off during operation, as excess fuel

washing into the engine oil will increase wear on engine

components.

NOTE: If the knob doesn’t stay where positioned, increase the

tension by rotating the tension adjusting nut (2) clockwise.

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OPERATION

Starting the Engine

7. Move the engine stop switch to RUN.

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

8. 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.

9. If the engine does not start, release the key and wait five seconds.

Activate the starter for another five seconds. Repeat this procedure

until the engine starts.

NOTE: If a warm engine has cooled to a point where it does not

readily start, intermittent use of the choke button (pulled half

way out) may be necessary. If the engine is over-choked

when warm, depress the throttle lever fully while cranking to

aid in starting. Release the throttle lever immediately after

the engine starts. If the engine does not start and all

conditions are favorable, change the spark plug and try

again.

10. If the engine slows, position the choke knob half way in to allow

proper engine warm up. Vary the engine RPM slightly with the

throttle to aid in warm-up. When the engine idles smoothly, push

the choke completely in.

CAUTION

Operating the vehicle immediately after starting could cause

engine damage. Allow the engine to warm up for several minutes

before operating the vehicle.

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OPERATION

Driving Safely

Driving Procedures

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

handlebars.

2. Start the engine and allow it to warm up, then shift the

transmission into gear.

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

4. Release the parking brake.

5. Slowly depress the throttle with your right thumb and begin

driving. Vehicle speed is controlled by the amount of throttle

opening.

6. Drive slowly. Practice maneuvering and using the throttle and

brakes on level surfaces.

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OPERATION

Driving Safely

Hauling Cargo

2/3

1/3

Accessory racks and hitches are available from your Polaris dealer.

Always read and understand the load distribution warnings on all

warning labels, and never exceed the specified weight capacities for the

vehicle.

Maximum Towing Capacities

Refer to the specifications at the rear of this manual for towing

capacities. When towing, reduce the rear rack cargo load capacity by

the amount of trailer tongue weight.

Never tow any trailer on a grade steeper than 15°.

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OPERATION

Driving Safely

Hauling Cargo

WARNING

Hauling cargo improperly can alter vehicle handling and may

cause loss of control or brake instability and result in serious

injury or death. Always follow these precautions when hauling

cargo:

S REDUCE SPEED AND ALLOW GREATER DISTANCE FOR

BRAKING WHEN HAULING CARGO.

S CARGO WEIGHT DISTRIBUTION should be 1/3 on the front

rack and 2/3 on the rear rack. When operating over rough or

hilly terrain, reduce speed and cargo to maintain stable driving

conditions. Carrying loads on one rack only increases the pos-

sibility of vehicle overturn.

S LOADS MUST BE CARRIED AS LOW ON THE RACKS AS

POSSIBLE. Carrying loads high on the racks raises the center

of gravity of the vehicle and creates a less stable operating

condition. When cargo loads are carried high on the racks, the

weight of the loads must be reduced to maintain stable operat-

ing conditions.

S ALL LOADS MUST BE SECURED BEFORE OPERATING.

Unsecured loads can create unstable operating conditions,

which could result in loss of control of the vehicle.

S OPERATE ONLY WITH STABLE AND SAFELY ARRANGED

LOADS. When handling off-centered loads that cannot be cen-

tered, securely fasten load and operate with extra caution. Al-

ways attach the tow load to the hitch point designated for your

vehicle.

S HEAVY LOADS CAN CAUSE BRAKING AND CONTROL

PROBLEMS. Use extreme caution when applying brakes with a

loaded vehicle. Avoid terrain or situations that may require

backing downhill.

S EXTREME CAUTION MUST BE USED when operating with

loads extending over the rack sides. Stability and maneuver-

ability may be adversely affected, causing the machine to over-

turn.

S DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carry-

ing loads on the front rack.

S DO NOT TRAVEL FASTER THAN THE RECOMMENDED

SPEEDS. Vehicle should never exceed 10 mph (16 kph) while

towing a load on a level grass surface. Vehicle speed should

never exceed 5 mph (8 kph) when towing loads in rough terrain,

while cornering, or while ascending or descending a hill.

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OPERATION

Driving Safely

Making Turns

Your Polaris ATV is equipped with a solid rear axle, which drives both

rear wheels equally at all times. This means that the wheel on the

outside of the turn must travel a greater distance than the inside wheel

when turning and the inside tire must slip traction slightly.

To make a turn, steer in the direction of the turn, leaning your upper

body to the inside of the turn while supporting your weight on the

outer footrest. This technique alters the balance of traction between the

rear wheels, allowing the turn to be made smoothly. The same leaning

technique should be used for turning in reverse.

NOTE: Practice making turns at slow speeds before attempting to

turn at faster speeds.

WARNING

Turning at sharp angles or at excessive speeds can result in

vehicle overturn and lead to serious injury. Avoid turning at sharp

angles. Never turn at high speeds.

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OPERATION

Driving Safely

Driving on Slippery Surfaces

Whenever riding on slippery surfaces such as wet trails or loose gravel,

or during freezing weather, follow these precautions:

1. Slow down when entering slippery areas.

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

quick, sharp turns which can cause skids.

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

and shifting your body weight forward.

WARNING

Failure to exercise care when operating on slippery surfaces can

result in loss of tire traction and cause loss of control, accident,

and serious injury or death.

Never apply the brakes during a skid.

Do not operate on excessively slippery surfaces.

Always reduce speed and use additional caution.

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OPERATION

Driving Safely

Driving Uphill

25_ Maximum

WARNING

Braking and handling are greatly affected when operating in hilly

terrain. Improper procedure could cause loss of control or

overturn and result in serious injury or death.

Avoid climbing steep hills (25_ maximum).

Use extreme caution when operating on hills, and follow proper

operating procedures outlined in the owner’s manual.

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OPERATION

Driving Safely

Driving Uphill

Whenever traveling uphill, follow these precautions:

1. Always travel straight uphill.

2. Avoid steep hills (25_ maximum).

3. Keep both feet on the footrests.

4. Transfer your weight forward.

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

6. Remain alert and be prepared to take emergency action.

This may include quick dismounting of the vehicle.

If all forward speed is lost:

Keep your weight uphill.

Apply the single lever brake, gradually. When fully stopped, apply the

auxiliary brake as well, then lock the park brake.

If the ATV begins rolling backwards:

Keep your weight uphill. Never apply engine power. Never apply the

auxiliary rear brake while rolling backwards.

Apply the single-lever brake, gradually. When fully stopped, apply the

auxiliary rear brake as well, and then lock the parking brake.

Dismount on uphill side, or to either side if ATV is pointed straight

uphill. Turn the ATV around and remount, following the procedure

described on page 54.

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OPERATION

Driving Safely

Driving Downhill

Whenever descending a hill, follow these precautions:

1. Proceed directly downhill.

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

3. Slow down.

4. Apply the brakes slightly to aid in slowing, using the single brake

lever.

NOTE: Familiarize yourself with operation of the auxiliary rear brake

pedal for additional braking in the event of normal service

brake loss.

WARNING

Excessive speed can cause loss of control and lead to serious

injury or death. Always operate slowly when traveling downhill.

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OPERATION

Driving Safely

Sidehilling

WARNING

Improperly crossing hills or turning on hills can result in loss of

control or vehicle overturn, resulting in severe injury or death.

Avoid crossing the side of a hill when possible. Follow proper

procedures as outlined in the owner’s manual.

Sidehilling can be a dangerous type of driving and should be avoided if

at all possible. If you do enter into a situation where sidehilling is

necessary, follow these precautions:

1. Slow down.

2. Lean into the hill, transferring your upper body weight toward the hill

while keeping your feet on the footrests.

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

NOTE: If the vehicle begins to tip, quickly turn the front wheel

downhill, if possible, or dismount on the uphill side

immediately!

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OPERATION

Driving Safely

Turning Around on a Hill

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

Use the K-turn to turn around.

8’ (2.4 m)

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

2. Leave the transmission in forward and shut off the engine.

3. Dismount on the uphill side of the vehicle, or on the left if the

vehicle is pointing straight uphill.

4. Staying uphill of the vehicle, turn the handlebars full left.

5. While holding the brake lever, release the parking brake lock and

slowly allow the vehicle to roll around to your right until it’s

pointing across the hill or slightly downward.

6. Lock the parking brake and remount the vehicle from the uphill

side, keeping body weight uphill.

7. Restart the engine with the transmission still in forward.

8. Release the parking brake and proceed slowly, controlling speed

with the brake, until the vehicle is on more level ground.

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OPERATION

Driving Safely

Driving Through Water

Your ATV can operate through water

with a maximum recommended

depth equal to the bottom of

the footrests (1). Follow

these procedures when

operating through water:

1. Determine water

depths and current

before crossing.

2. Choose a crossing

where both banks have

gradual inclines.

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

4. After crossing, dry the brakes by applying light pressure to the

lever until braking action is normal.

After running the vehicle in water, it’s critical to have it serviced as

outlined in the maintenance chart. See page 60. The following areas

need special attention: engine oil, transmission oil, front and rear

gearcases (if equipped), and all grease fittings.

CAUTION

Major engine damage can result if the vehicle is not thoroughly

inspected after operation in water. Perform the services outlined

in the maintenance chart.

If your vehicle becomes immersed or is operated in water that

exceeds the footrest level, take it to your dealer for service before

starting the engine.

NOTE: Avoid operating the vehicle through deep or fast-flowing

water. If you cannot avoid water that exceeds the

recommended maximum depth, go slowly, balance your

weight carefully, avoid sudden movements, and maintain a

slow and steady forward motion. Do not make sudden turns

or stops, and do not make sudden throttle changes.

If your vehicle becomes immersed, and it’s impossible to take it to a

dealer before starting it, follow the steps described on page 87. Have

the vehicle serviced by your dealer at the first opportunity.

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OPERATION

Driving Safely

Driving Over Obstacles

Be alert! Look ahead and learn to read the terrain you’re traveling on.

Be constantly alert for hazards such as logs, rocks and low hanging

branches.

WARNING

Severe injury or death can result if your vehicle comes in contact

with a hidden obstacle. Not all obstacles are immediately visible.

Travel with caution in unfamiliar terrain.

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OPERATION

Driving Safely

Driving in Reverse

Follow these precautions

when operating in reverse:

1. Always avoid backing

downhill.

2. Back slowly.

3. When in reverse,

apply the brakes

lightly for stopping.

4. Avoid turning at sharp

angles in reverse.

5. Never open the throttle

suddenly while backing.

WARNING

Failure to use caution when operating in reverse can result in

serious injury or death. Before shifting into reverse, always check

for obstacles or people behind the vehicle. When it’s safe to

proceed, back slowly.

Do not use the override switch unless additional power is required

for vehicle movement. Use with caution.

Avoid backing on inclines, and avoid turning at sharp angles.

NOTE: This Polaris ATV is equipped with a reverse speed limiter.

The override button should be used with caution as rearward

vehicle speed is greatly increased. Do not operate at wide

open throttle. Open the throttle just enough to maintain a

desired speed.

CAUTION

Excessive throttle operation while in the speed limit mode may

cause fuel to build in the exhaust, resulting in engine popping

and/or engine damage.

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OPERATION

Driving Safely

Parking on an Incline

Avoid parking on an incline if possible. If it’s unavoidable, follow

these precautions:

1. Turn the engine off.

1. Place the transmission in gear.

2. Set the parking brake.

3. Always block the rear wheels on the downhill side. See

illustration.

4. Shut off the fuel supply.

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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 USDA Forest Service Standard 5100-1C.

Federal law requires that this spark arrestor be installed and functional

when the vehicle is operated on public lands.

Operation of off-road vehicles on public lands in the U.S.A. is

regulated by 43 CFR 8343.1(c). Violations are subject to monetary

penalties. Federal regulations can be viewed online at

www.gpoaccess.gov/ecfr/.

Crankcase Emission Control System

This engine is equipped with a closed crankcase system. Blow-by

gases are forced back to the combustion chamber by the intake system.

All exhaust gases exit through the exhaust system.

Exhaust Emission Control System

The emissions from the exhaust of this vehicle are controlled by engine

design, including factory-set fuel delivery and ignition. The engine

and related components must be maintained at Polaris specifications to

achieve optimal performance.

Engine idle speed is the only adjustment Polaris recommends that the

operator perform. Any other adjustments should be performed by an

authorized Polaris dealer.

The emissions label is located on the left front portion of the frame or

under the seat.

Electromagnetic Interference

This spark ignition system complies with Canadian ICES-002.

This vehicle complies with the EMC requirements of European

directives 97/24/EC and 89/336/EEC.

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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 116.

NOTE: Service and adjustments are important for proper vehicle

operation. If you’re not familiar with safe service and

adjustment procedures, have a qualified dealer perform

these operations.

Maintenance intervals in the following chart are based upon average

riding conditions and an average vehicle speed of approximately 10

miles per hour. Vehicles subjected to severe use must be inspected and

serviced more frequently.

Severe Use Definition

S Frequent immersion in mud, water or sand

S Racing or race-style high RPM use

S Prolonged low speed, heavy load operation

S Extended idle

S Short trip cold weather operation

Pay special attention to the oil level. A rise in oil level during cold

weather can indicate contaminants collecting in the oil sump or

crankcase. Change oil immediately if the oil level begins to rise.

Monitor the oil level, and if it continues to rise, discontinue use and

determine the cause or see your dealer.

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MAINTENANCE

Periodic Maintenance Chart

Maintenance Chart Key

Perform these procedures more frequently for vehicles subjected to

severe use.

Emission-related service (Failure to conduct this maintenance will

not void the emissions warranty but may affect emissions.)

Have an authorized Polaris dealer perform these services.

WARNING

Improperly performing the procedures marked with a J could

result in component failure and lead to serious injury or death.

Have an authorized Polaris dealer perform these services.

Perform all services at whichever maintenance interval is reached first.

Item

Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar

Miles

(Km)

Steering

Pre-Ride

Daily

Make adjustments as need-

ed. See Pre-Ride Checklist

on page 42.

Front suspension

Rear suspension

Tires

Brake fluid level

Brake lever travel

Brake system

Wheels/fasteners

Frame fasteners

Engine oil level

Air filter, pre-filter

Inspect; clean often; replace

as needed

Air box sediment

tube

Daily

Drain deposits when visible

Coolant

(if applicable)

Check level daily, change

coolant every 2 years

Headlamp/tail

lamp

Daily

Check operation; apply

dielectric grease if replacing

Air filter,

main element

Weekly

Inspect; replace as needed

Recoil housing

Drain water as needed,

check often if operating in

wet conditions

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MAINTENANCE

Periodic Maintenance Chart

Item

Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar

Miles

(Km)

Brake pad wear

10 H

Monthly

100 (160)

Inspect periodically

Battery

20 H

25 H

Monthly

200 (320)

250 (400)

Check terminals; clean; test

Inspect level; change yearly

Inspect; clean if needed

Transmission oil

Engine breather

filter (if equipped)

General

50 H

3 M

6 M

500 (800)

Lubricate all fittings, pivots,

cables, etc.

lubrication

Carburetor float

bowl

Drain bowl periodically and

prior to storage

Throttle Cable/

ETC Switch

Inspect; adjust; lubricate;

replace if necessary

Choke cable

Inspect; adjust; lubricate;

replace if necessary

Carburetor air

intake ducts/

flange

Inspect ducts for proper

sealing/air leaks

Drive belt

50 H

6 M

500 (800)

Inspect; adjust; replace as

needed

Cooling system

(if applicable)

1000 (1600) Inspect coolant strength

seasonally; pressure test

system yearly

Engine oil change 100 H

6 M

1000 (1600) Perform a break-in oil

change at one month

Oil filter change

100 H

6 M

12 M

1000 (1600) Replace with oil change

1000 (1600) Inspect routing, condition

1000 (1600) Inspect; adjust

Oil tank vent hose 100 H

Valve clearance

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

Radiator

(if applicable)

100 H

12 M

1000 (1600) Inspect; clean external

surfaces

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MAINTENANCE

Periodic Maintenance Chart

Item

Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar

Miles

(Km)

Cooling hoses

(if applicable)

100 H

12 M

1000 (1600) Inspect for leaks

Engine mounts

100 H

12 M

1000 (1600) Inspect

Exhaust muffler/

pipe

Spark plug

Ignition Timing

Wiring

100 H

12 M

1000 (1600) Inspect; replace as needed

1000 (1600) Inspect

1000 (1600) Inspect for wear, routing,

security; apply dielectric

grease to connectors

subjected to water, mud, etc.

Clutches (drive

and driven)

100 H

12 M

1000 (1600) Inspect; clean; replace worn

parts

Front wheel

bearings

1000 (1600) Inspect; replace as needed

Brake fluid

200 H

300 H

24 M

36 M

2000 (3200) Change every two years

3000 (4800) Clean out

Spark arrestor

Idle speed

Adjust as needed

Toe adjustment

Inspect periodically; adjust

when parts are replaced

Headlight aim

Adjust as needed

Perform these procedures more often for vehicles subjected to severe use.

Emission-Related Service

Have an authorized Polaris dealer perform these services.

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MAINTENANCE

Lubrication Recommendations

Check and lubricate all components at the intervals outlined in the

Periodic Maintenance Chart beginning on page 60. Items not listed in

the chart should be lubricated at the General Lubrication interval.

NOTE: The a-arms and lower 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.

Lubrication Chart Key

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

L Polaris Premium All Season Grease or grease conforming to NLG

No. 2, such as Conoco Superlube M or Mobilegrease Special

Use Polaris Premium U-Joint Lube every 500 miles, before long

periods of storage, or after pressure washing or submerging

When suspension action becomes stiff, or after washing

∆

Item

Engine Oil

Lube

Method

PS-4 PLUS Performance Add to proper level on dipstick.

Synthetic 2W-50

Brake Fluid

DOT 4 fluid only

Maintain level between fill lines.

See page 35.

Drive chain(s)

(1) Transmission

O-ring chain lube or SAE Lubricate.

80/90

AGL Synthetic

Gearcase Lube

Maintain as recommended on

page 68.

(2) Swing Arm

Bushings

Locate fittings on swing arm and

grease with grease gun.

"LGrease

(3) Tie Rod Ends

Lift boot, clean away dirt and

grease, apply fresh grease by

hand and reassemble.

"L∆Grease

(4) Axle Housing

Locate fittings on swing arm and

grease with grease gun.

"L Grease

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MAINTENANCE

Lubrication Recommendations

(2)

(4)

(1)

(3)

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MAINTENANCE

Engine Oil

Always check and change the engine oil at the intervals outlined in the

Periodic Maintenance Chart beginning on page 60. Always change the

oil filter whenever changing oil.

Oil Recommendations

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.

See page 107 for the part numbers of Polaris products.

CAUTION

Mixing brands or using a non-recommended oil may cause

serious engine damage. Always use the recommended oil.

Never substitute or mix oil brands.

Oil Check

The oil fill is located on the left side of the vehicle (1).

1. Position the machine on a level surface.

2. Start the engine and let it idle for 20-30 seconds. Stop the engine.

3. Remove the dipstick and wipe it dry with a clean cloth.

4. Screw the dipstick completely in.

5. Remove the dipstick and read the oil level. Maintain the oil level in

the safe operating range (2). Do not overfill.

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MAINTENANCE

Engine Oil

Oil and Filter Change

1. Position the vehicle on a level surface.

2. Clean the area around the drain plug.

3. Run the engine for two to three minutes until warm. Stop the

engine.

CAUTION

Contact with hot oil may result in serious burns. Do not allow hot

oil to come into contact with skin.

4. Place a drain pan beneath the engine crankcase and remove the

drain plug.

5. Allow the oil to drain completely.

6. Install a new sealing washer on the drain plug.

NOTE: The sealing surfaces on the drain plug and crankcase should

be clean and free of burrs, nicks or scratches.

7. Reinstall the drain plug and torque to 14 ft. lbs. (19 Nm).

8. Place shop towels beneath the oil filter. Using an oil filter wrench,

turn the filter counterclockwise to remove.

9. Using a clean, dry cloth, clean the filter sealing surface on the

crankcase.

10. Lubricate the gasket on the new filter with a film of engine oil.

Check to make sure the gasket is in good condition.

11. Install the new filter and turn by hand until the filter gasket

contacts the sealing surface, then turn and additional 1/2 turn.

12. Remove the dipstick and fill the sump with 1.7 quarts (1.6 l) of the

recommended oil.

13. Place the gear selector in neutral and set the parking brake.

14. Start the engine and let it idle for one to two minutes. Stop the

engine and inspect for leaks.

15. Recheck the oil level and add oil as necessary to bring the level to

the upper mark on the dipstick.

16. Dispose of used filter and oil properly.

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MAINTENANCE

Transmission Oil

Always check and change the transmission oil at the intervals outlined

in the Periodic Maintenance Chart beginning on page 60. Maintain the

oil level at the bottom of the fill hole threads. We recommend the use

of Premium AGL Synthetic Gearcase Lubricant. See page 107 for the

part numbers of Polaris products.

Oil Check

The transmission dipstick (1) is

located on the right side of the

machine near the recoil handle.

NOTE: We recommend the use

of Polaris Premium AGL

Synthetic Gearcase Lube.

See page 107 for the part

numbers of Polaris

products.

1. Position the ATV on a level

surface. Remove the dipstick

and wipe it clean.

2. Reinstall the dipstick completely, then remove it and check the

level. Add the recommended lubricant to bring the level into the

safe operating range. See Specifications beginning on page 104 for

capacity.

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MAINTENANCE

Transmission Oil

Oil Change

1. Place a drain pan beneath the

transmission oil drain plug

area.

2. Loosen the jam nut (A).

3. Turn the adjuster bolt (B) in to

allow the removal of the drain

plug (C).

4. Remove the drain plug and

wipe the magnetic end clean to

remove accumulated metallic

filings.

5. After the oil has drained

completely, install a new

sealing washer and reinstall the drain plug. Torque to 14 ft. lbs.

(19 Nm).

6. Turn the adjuster bolt (B) out until it touches the frame, and then

turn an additional 1/2 turn.

7. Tighten the jam nut securely while holding the adjuster bolt.

8. Add the recommended lubricant through the dipstick hole until the

oil level is between the upper and lower limits. Do not overfill.

9. Check for leaks.

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MAINTENANCE

Toe Alignment

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.

Use the following procedure to check the toe alignment of the vehicle.

The recommended toe alignment is 1/8″ to 1/4″ toe out.

1. Position the vehicle on a level

surface.

2. Set the handlebars in a

straight-ahead position

and secure them in this

position.

3. Place a chalk mark on the

center line of the front

tires approximately 10″

(25.4 cm) from the floor,

or as close to the hub/axle

center line as possible.

Make sure both marks are

the same distance from

the floor.

4. Measure the distance between the marks and record the

measurement (A).

5. Move the vehicle until the chalk marks are at the rear of the tires,

even with the hub/axle centerline.

6. Measure the distance between the marks and record the

measurement (B).

7. Subtract measurement B from measurement A. The difference is

the vehicle toe-out alignment.

NOTE: If you discover improper alignment, see your Polaris dealer

for service.

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MAINTENANCE

Brakes

The front and rear brakes are hydraulic disc brakes, activated by

moving the single brake lever toward the handlebar. These brakes are

self-adjusting.

The following checks are recommended to keep the brake system in

good operating condition. Check more often if brakes are used heavily

under normal operation, such as in hilly country or in muddy terrain.

WARNING

Never store or use a partial bottle of brake fluid. Brake fluid is

hygroscopic, meaning it rapidly absorbs moisture from the air.

The moisture causes the boiling temperature of the brake fluid to

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

accident or severe injury. After opening a bottle of brake fluid,

always discard any unused portion.

1. Always maintain brake fluid at an adequate level (see page 35).

WARNING

An over-full master cylinder may cause brake drag or brake

lock-up, which could result in serious injury or death. Maintain

brake fluid at the recommended level. Do not overfill.

NOTE: 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. Always fill the reservoir as needed

whenever the cover is loosened or removed to ensure proper

diaphragm operation. Use Polaris DOT 4 brake fluid. Do not

overfill.

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MAINTENANCE

Brakes

1. Check the brake system for fluid leaks.

2. Check the brakes for excessive travel or

spongy feel.

3. Check the friction pads for wear,

damage and looseness.

4. Check the security and surface

condition of the disc.

NOTE: Pads should be changed when

worn to 3/64″ (.1 cm).

3/64″ (.1 cm)

Auxiliary Brake

The auxiliary brake system is intended to be used as a backup for the

main brake system. Should the main system fail, the rear brake can be

activated by depressing the foot pedal on the inside of the right

footrest. The hydraulic auxiliary brake system requires no adjustment.

NOTE: Since this is a rear brake only, it will not be as effective as

the all-wheel single lever system.

Steering Assembly

The steering assembly of the ATV should be checked periodically for

loose nuts and bolts. If loose nuts and bolts are found, see your Polaris

dealer for service before operating the vehicle.

Camber and Caster

The camber and caster are non-adjustable.

Rear Spring

The rear shock absorber spring is

adjusted by rotating the adjuster (1)

either clockwise or counterclockwise

to increase or decrease spring

tension.

NOTE: Accessory springs are

available through your

Polaris dealer.

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MAINTENANCE

Throttle Cable Freeplay

Throttle cable freeplay is adjusted at the handlebar.

1. Locate the throttle cable

adjuster on the

handlebar.

2. Squeeze the end of the

rubber boot (1) and slide

it far enough to expose

the end of the inline

cable adjuster (2).

3. Loosen the locknut (3).

4. Rotate the boot to turn

the adjuster until 1/16″

to 1/8″ (2-3 mm)

freeplay is achieved at

the thumb lever.

NOTE: While adjusting

freeplay, be sure

to flip the throttle

lever back and

forth.

5. Tighten the locknut.

6. Squeeze the end of the

rubber boot and slide it

over the cable adjuster to

its original position.

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MAINTENANCE

Handlebars

WARNING

Improper adjustment of the handlebars or incorrect torquing of

the adjuster block tightening bolts can cause limited steering or

loosening of the handlebars, resulting in loss of control and

possible serious personal injury or death. Follow the adjustment

procedures exactly, or see your Polaris dealer for service.

The handlebars can be adjusted for

rider preference.

1. Remove the handlebar cover to

access the handlebar bolts (1).

2. Loosen the four bolts.

3. Adjust the handlebar to the

desired height. Be sure the

handlebars do not contact the

gas tank or any other part of the

machine when turned fully to

the left or right.

4. Torque the two front bolts to 10-12 ft. lbs. (14-17 Nm), then

torque the two rear bolts. A gap of up to 1/8” will remain at the

rear bolts.

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MAINTENANCE

Carburetor

IMPORTANT: Your Polaris ATV is calibrated at the factory for

optimal performance at altitudes ranging from zero to 6,000 feet (1800

m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above

6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and

the engine loses approximately 3% of its power for each 1000-foot

(304.8 m) increase in elevation. Although this power cannot be

regained, adjustments to the carburetor and drive system can be made

to allow more efficient operation. Optional jets, available from your

Polaris dealer, are required for operation above 6,000 feet and

temperatures below +40 degrees F. (4 degrees C.)

NOTE: Continuous operation of the engine without proper jetting

when required can cause poor performance, overheating and

engine or PVT damage. See your Polaris dealer for more

information about jetting the ATV for conditions in your area.

If the engine idle speed is not satisfactory, and all other conditions are

favorable, the carburetor can be adjusted.

1. Warm up the engine by running the

vehicle for approximately five minutes.

2. Place the transmission in gear and engage

the parking brake.

3. Adjust the carburetor idle screw (1) either

in or out until the desired idle RPM is

reached. Refer to the specifications

section beginning on page 104 for the

proper setting.

NOTE: Turn the screw in (clockwise) to raise

RPM. Turn the screw out

(counterclockwise) to lower RPM.

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MAINTENANCE

Wheels

WARNING

Operating your ATV with worn tires, improperly inflated tires,

non-standard tires or improperly installed tires will affect vehicle

handling and could cause an accident resulting in serious injury or

death.

Maintain proper tire pressure as described on the decal on your

ATV and in your owner’s manual.

Always use original equipment size and type when replacing tires.

Make sure the wheels are installed properly.

Always replace tires when the tread depth measures 1/8″ (.3 cm)

or less.

Wheel Removal

1. Stop the engine, place the transmission in gear and lock the

parking brake.

2. Loosen the wheel nuts slightly.

3. Elevate the side of the vehicle by placing a suitable stand under the

footrest frame.

4. Remove the wheel nuts and remove the wheel.

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MAINTENANCE

Wheels

Wheel Installation

1. Place the transmission in gear and lock the parking brake.

WARNING

Improperly installed wheels can adversely affect tire wear and

vehicle handling, which can result in serious injury or death.

Always ensure that all nuts are torqued to specification. Do not

service axle nuts that have a cotter pin installed. See your

Polaris dealer.

2. Place the wheel on the wheel hub with the valve stem toward the

outside and rotation arrows on the tire pointing toward forward

rotation.

3. Install the wheel nuts and finger tighten. On vehicles with tapered

rear wheel nuts, make sure the tapered ends of the nuts fit into the

tapers on the wheels.

4. Lower the vehicle to the ground.

5. Torque the nuts to specification.

Wheel Nut Torque Specifications

Check the wheel nut torques occasionally and when they’ve been

loosened for maintenance.

Item

Specification

27 ft. lbs. (37 Nm)

50 ft. lbs. (68 Nm)

Front Wheel Nuts

Rear Wheel Nuts

Front

Rear

50 ft. lbs.

(68 Nm)

27 ft. lbs.

(37 Nm)

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MAINTENANCE

Wheels

Front Wheel Hub Tightening

Front wheel bearing tightness and spindle nut retention are critical

component operations. All service must be performed by your

authorized Polaris dealer.

Tire Tread Depth

Always replace tires when tread

depth is worn to 1/8″ (.3 cm) or less.

See illustration.

1/8I (.3 cm)

WARNING

Operating the vehicle with worn tires will increase the possibility

of skidding, which could lead to loss of control and serious injury

or death. Always replace tires when the tread depth measures

1/8″ (.3 cm) or less.

WARNING

Use of non-standard size or type of tires or improper tire inflation

may adversely affect vehicle maneuverability and cause loss of

control resulting in serious injury or death. Maintain proper tire

pressure as outlined in this owner’s manual. When replacing a

tire always use original equipment size and type.

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MAINTENANCE

Drive Chain

Polaris ATV drive chains are equipped with o-ring-sealed, permanently

greased pins and rollers. However, the outer surfaces of the roller must

be lubricated.

Always inspect the drive chain prior to operating the vehicle. Check for

damaged or missing o-rings or damaged rollers. Also check for correct

slack adjustment. Maintain the stone guard to rear sprocket clearance

at 1/8″ (.3 cm).

Regularly lubricate the drive chain with Polaris Chain Lube, an SAE

80-90 lube or an approved o-ring chain spray lube. See page 107 for the

part numbers of Polaris products.

CAUTION

Washing the drive chain with a high pressure washer or gasoline

can cause damage to the o-rings, causing premature wear and

drive chain failure. Do not use a high pressure washer or gasoline

to clean the drive chain.

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MAINTENANCE

Drive Chain

Rear Drive Chain Slack

CAUTION

Adjusting or operating the ATV with improper rear drive chain

slack can result in severe damage to the transmission and drive

components. Always make sure the slack is within the stated

specifications.

Check the amount of chain slack in three different locations by moving

the vehicle slightly forward to gain slack at the top side of the rear

chain. Measure the chain slack at the tightest of the three positions. At

this point the chain should have 3/16″-3/8″ (.48 cm - .95 cm)

deflection. Use the following procedure if adjustment is required.

3/16″-3/8″ (.48 cm - .95 cm)

1. Remove the chain guard.

2. Loosen the chain guide.

3. Loosen the two eccentric

locking bolts (1).

4. Loosen the caliper mounting

bolt located on the left side

of the swing arm.

5. Insert a pin punch (2) through the sprocket hub and into the

eccentric housing.

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MAINTENANCE

Drive Chain

Rear Drive Chain Slack

6. Roll the ATV forward or backward

to adjust the chain slack to the

proper tension. See the illustration

for proper splice link clip opening

position (1).

7. Tighten the eccentric locking bolts

to 30 ft. lbs. (41 Nm) for machines

without the hitch and 45 ft. lbs. (61

Nm) for machines with a hitch.

8. Tighten the caliper mount bolt to 15 ft. lbs. (20 Nm).

9. Remove the pin punch.

10. Roll the ATV forward, checking chain tension in several places

around the chain.

NOTE: The chain is adjusted correctly when the tightest portion of

the chain has approximately 3/8” (10mm) deflection.

11. Position the chain guide to allow 1/8” (3mm) clearance and tighten

the retaining bolt to 5 ft. lbs. (7 Nm).

12. Reinstall the chain guard.

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MAINTENANCE

Lights

When servicing a halogen lamp, don’t touch the lamp with bare

fingers. Oil from your skin leaves a residue, causing a hot spot that

will shorten the life of the lamp.

WARNING

Poor lighting while driving can result in severe injury or death.

Headlight and taillight lenses become dirty during normal

operation. Wash the headlights frequently to maintain lighting

quality.

Hot components can cause serious burns to skin. Do not service

the headlamps until they’ve cooled sufficiently.

Headlight Lamp Replacement

1. Remove the front cover and unplug the light harness.

2. Remove the rubber cap from the back of the headlight to reveal the

retention screw.

3. Remove the small phillips head screw, and carefully remove the

bulb from the housing.

4. Insert the new bulb into the housing and reinstall the retention

screw. Reinstall the rubber cap.

5. Reconnect the light harness and reinstall the cover.

6. Adjust the headlight aim if necessary.

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MAINTENANCE

Lights

Taillight/Brakelight Lamp Replacement

If the taillight/brakelight does not work the lamp may need to be

replaced.

1. Remove the taillight lens cover

mounting screws. Remove the

lens cover and gasket and set

aside for reassembly.

2. Remove the lamp (1).

3. Apply dielectric grease to the

socket and install the new

lamp.

4. Test the taillight/brakelight for

proper operation.

5. Reinstall the gasket and lens cover.

Indicator Lamp Replacement

1. Remove the instrument panel, if necessary, to access the back of

the indicator panel.

2. Using a small, straight-blade screwdriver, turn the base of the bulb

1/4 turn counterclockwise.

3. Using a needle-nose plier or similar tool, pull the lamp out of the

indicator panel housing.

4. Insert the new bulb and seat it by turning it 1/4 turn clockwise.

5. Reinstall the instrument panel if removed.

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MAINTENANCE

Air Filter

1. Remove the seat, release the

clips, and remove the air box

cover.

2. Loosen the clamp and remove the

filter.

3. If equipped, remove the fabric

type pre-filter (1) from the main

filter (2). Wash the pre-filter in

soapy water, then rinse and let

dry. Reinstall the pre-filter over

the main filter.

4. Replace the main filter with a

new filter if needed.

5. Reinstall the filter into the air box

and tighten the clamp. Do not

over tighten the clamp, as filter

damage could occur.

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MAINTENANCE

Spark Plugs

Spark Plug Recommendations

CAUTION

Using non-recommended spark plugs can result in serious engine

damage. Always use Polaris-recommended spark plugs. Refer

to the specifications section beginning on page 104.

Refer to the specifications section beginning on page 104 for the

recommended spark plug type and gap for your vehicle. Torque spark

plugs to specification.

Plug Condition

New Spark Plug

Torque Specification

9-11 ft. lbs. (12-15 Nm)

17-20 ft. lbs. (23-27 Nm)

Previously Installed Spark Plug

Spark Plug Inspection

Spark plug condition is indicative of engine operation. Check the spark

plug firing end condition after the engine has been warmed up and the

vehicle has been driven at higher speeds. Immediately check the spark

plug for correct color. See page 86.

WARNING

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. Using the special wrench provided in the tool pouch, rotate the

spark plug counterclockwise to remove it.

3. Reverse the procedure for spark plug installation. Torque to

specification.

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MAINTENANCE

Spark Plugs

Spark Plug Inspection

Normal Plug

The normal insulator tip is gray, tan or light brown. There will be few

combustion deposits. The electrodes are not burned or eroded. This

indicates the proper type and heat range for the engine and the service.

NOTE: The tip should not be white. A white insulator tip indicates

overheating, caused by use of an improper spark plug or

incorrect carburetion adjustments.

Wet Fouled Plug

The wet fouled insulator tip is black. A damp oil film covers the firing

end. There may be a carbon layer over the entire nose. Generally, the

electrodes are not worn. General causes of fouling are excessive oil,

use of non-recommended injection oil, improper use of the choke, or

incorrect carburetion adjustments.

Recoil Housing

To prevent possible engine damage,

always drain the recoil housing (1)

after operating the ATV in very wet

conditions. This should also be

done before storing the ATV.

Water will enter the recoil housing

if the starter handle is disengaged

from the rope guide when under

water.

The drain screw is located at the

bottom of the recoil housing. Use a

wrench to remove the screw. Be sure to reinstall the screw after

draining the housing.

NOTE: Do not open the crankcase drain unless the engine has

ingested water. On 4-cycle engines, some engine oil will be

lost if the crankcase drain is opened.

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MAINTENANCE

Vehicle Immersion

CAUTION

If your vehicle becomes immersed, major engine damage can

result if the machine is not thoroughly inspected. Take the

vehicle to your dealer before starting the engine.

If it’s impossible to take your ATV to a dealer before starting it, follow

the steps outlined below.

1. Move the ATV to dry land or at the

very least, to water below the

footrests.

2. Check the airbox for any water. Drain

and dry it if water is present.

3. Turn the fuel valve off.

4. Remove the spark plug.

5. Turn the engine over several times

using the electric start.

6. Loosen the carburetor drain screw (1).

7. Dry the spark plug and reinstall, or replace it with a new plug.

8. Tighten the carburetor drain screw.

9. Turn the fuel valve on.

10. Attempt to start the engine. If necessary, repeat the drying

procedure.

11. Take the ATV to your dealer for service as soon as possible,

whether you succeed in starting it or not.

NOTE: If water has been ingested into the PVT, follow the procedure

on page 89 for drying out the PVT.

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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.” This

begins to occur at speeds of less than 5 MPH, due to the system’s

dependence on engine speed.

For example, when operating at a ground speed of 3 MPH, the engine

would be running at only about 1500 RPM, with an engagement speed

of about 1400 RPM. Whenever operating this close to the engagement

point, the engine may be running at a speed too low to provide the

adequate “pinch” needed to prevent incomplete engagement.

Incomplete engagement creates excessive heat that can destroy belts

and clutch covers. In some cases, excessive clutch wear and damage

may result.

If the ATV will be operated for extended periods below 5 MPH, or for

towing loads, we recommend that you install a one tooth smaller

counter shaft sprocket to raise the operating RPM far enough above the

engagement RPM to reduce heat caused by incomplete engagement.

Reducing the temperature inside the clutch cover extends the life of the

PVT components (belt, cover, etc.).

NOTE: Avoid heavy pulling and extended low-speed

operation.

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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. Extensive engineering and

testing has been conducted to ensure the safety of this product.

However, as the owner, you have the following responsibilities to

make sure this system remains safe:

Always follow all recommended maintenance procedures. See

your dealer as outlined in the owner’s manual.

This PVT system is intended for use on Polaris products only. Do

not install it in any other product.

Always make sure the PVT housing is securely in place during

operation.

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. Remove the drain plug and allow the water to drain. Reinstall the

drain plug.

2. Start the engine and shift the transmission into neutral. Apply

varying throttle for 10-15 seconds to expel the moisture and air-dry

the belt and clutches. Do not hold the throttle wide open for more

than 10 seconds.

3. Allow the engine RPM to settle to idle speed, then shift the

transmission to the lowest available range.

4. Test for belt slippage. If the belt slips, repeat the process.

5. Take the vehicle to your dealer for service as soon as possible.

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MAINTENANCE

Spark Arrestor

WARNING

Failure to heed the following warnings while servicing the spark

arrestor could result in serious injury or death.

Do not perform service on the spark arrestor while the system is

hot. Exhaust system temperatures can reach 1000° F. Allow

components to cool sufficiently before proceeding.

Remove any combustible materials from the area.

Wear eye protection and leather work gloves.

Do not stand behind or in front of the vehicle while purging.

Never run the engine in an enclosed area. Exhaust contains

poisonous carbon monoxide gas.

Never go under the vehicle while it’s inclined.

1. Remove the arrestor clean-out

plug (1) from the bottom of the

muffler.

2. Place the transmission in neutral

and start the engine.

3. Purge carbon from the system by

momentarily revving the engine

several times.

4. If carbon is expelled, cover or plug the

exhaust outlet (2) and rap on the pipe around

the cleanout plug while revving the engine several more times.

5. If particles are still suspected to be in the muffler, elevate the rear

of the vehicle one foot higher than the front. Set the parking brake

and block the wheels. Make sure the vehicle is in neutral and

repeat steps 3 and 4 until no more particles are expelled when the

engine is revved.

6. Stop the engine and allow the arrestor to cool. Reinstall the

arrestor plug and remove the outlet cover or plug.

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MAINTENANCE

Battery

Your ATV 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.

Rinse well with tap water and dry off with clean shop towels. Coat the

terminals with dielectric grease or petroleum jelly. Be careful not to

allow cleaning solution or tap water into a conventional battery.

Conventional Battery

WARNING

Battery electrolyte is poisonous. It contains sulfuric acid. Serious

burns can result from contact with skin, eyes or clothing.

Antidote:

External: Flush with water.

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

of magnesia, beaten egg, or vegetable oil. Call physician

immediately.

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

attention.

Batteries produce explosive gases. Keep sparks, flame,

cigarettes, etc. away. Ventilate when charging or using in an

enclosed space. Always shield eyes when working near

batteries. KEEP OUT OF REACH OF CHILDREN.

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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. Disconnect the hold-down strap holding the battery in position, and

remove battery cover.

2. On conventional batteries, remove the battery vent tube.

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

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

5. Lift the battery out of the ATV. Be careful not to tip a conventional

battery sideways, which could spill electrolyte.

CAUTION

If electrolyte spills, immediately wash it off with a solution of one

tablespoon baking soda and one cup water to prevent damage to

the vehicle.

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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 pages 95-97

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).

NOTE: 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.

WARNING

Battery gases could accumulate in an improperly installed vent

tube and cause an explosion, resulting in serious injury or death.

Always ensure that the vent tube is free of obstructions and is

securely installed as recommended.

4. On conventional batteries, coat the terminals with dielectric grease

or petroleum jelly.

5. Connect and tighten the red (positive) cable first.

6. Connect and tighten the black (negative) cable last.

7. Install the battery cover.

8. Secure the battery hold-down strap.

9. Verify that cables are properly routed.

NOTE: Cables should be safely tucked away at the front and rear of

the battery.

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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.

NOTE: Power plug leads may need to be bent down so that the

battery cover can be installed.

NOTE: Battery charge can be maintained by using a Polaris Battery

Tender charger or by charging about once a month to make

up for normal self-discharge. Battery Tender can be left

connected during the storage period, and will automatically

charge the battery if the voltage drops below a

pre-determined point. See page 107 for the part numbers of

Polaris products.

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MAINTENANCE

Battery

Battery Fluid (Conventional Battery)

A poorly maintained battery will

deteriorate rapidly. Check the battery

fluid level often. Maintain the fluid

level between the upper and lower level

marks (1).

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 92.

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 93. Make sure the positive terminal

is toward the front of the vehicle.

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MAINTENANCE

Battery

Battery Charging (Sealed Battery)

The following battery charging instructions apply only to the

installation of a sealed battery. Read all instructions before proceeding

with the installation of this battery.

The sealed battery is already filled with electrolyte and has been sealed

and fully charged at the factory. Never pry the sealing strip off or add

any other fluid to this battery.

The single most important thing about maintaining a sealed battery is

to keep it fully charged. Since the battery is sealed and the sealing strip

cannot be removed, you must use a voltmeter or multimeter to measure

DC voltage.

WARNING

An overheated battery could explode, causing severe injury or

death. Always watch charging times carefully. Stop charging if the

battery becomes very warm to the touch. Allow it to cool before

resuming charging.

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.

NOTE: When using an automatic charger, refer to the charger

manufacturer’s instructions for recharging. When using a

constant current charger, use the following guidelines for

recharging.

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MAINTENANCE

Battery

Battery Charging (Sealed Battery)

NOTE: Always verify battery condition before and 1-2 hours after the

end of charging.

State of

Charge

Voltage

Action

Charge Time*

(Using constant current

charger @ standard amps

specified on top of battery)

100%

12.8-13.0 volts

12.5-12.8 volts

None, check at

3 mos. from date of

manufacture

None required

75%-100%

May need slight

charge, if no

charge given,

check in 3 months

3-6 hours

50%-75%

25%-50%

12.0-12.5 volts

11.5-12.0 volts

Needs Charge

5-11 hours

At least 13 hours,

verify state of charge

0%-25%

11.5 volts or less

Needs Charge

At least 20 hours

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MAINTENANCE

Cleaning and Storage

See page 107 for the part numbers of Polaris products.

Washing the Vehicle

Keeping your ATV clean will not only improve its appearance but it

can also extend the life of various components.

CAUTION

High water pressure may damage ATV components. Polaris

recommends washing the vehicle by hand or with a garden hose,

using mild soap.

Certain products, including insect repellants and chemicals, will

damage plastic surfaces. Do not allow these types of products to

come into contact with the vehicle.

The best and safest way to clean your Polaris vehicle is with a garden

hose and a pail of mild soap and water.

1. Use a professional--type washing cloth, cleaning the upper body

first and the lower parts last.

2. Rinse with clean water frequently.

3. Dry surfaces with a chamois to prevent water spots.

Washing Tips

S Avoid the use of harsh cleaners, which can scratch the finish.

S Do not use a power washer to clean the vehicle.

S Do not use medium to heavy duty compounds on the finish.

S Always use clean cloths and pads for cleaning and polishing. Old or

reused cloths and pads may contain dirt particles that will scratch the

finish.

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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:

S Wheel bearings

S Radiator (if equipped)

S Transmission seals

S Brakes

S Cab and body panels

S Labels and decals

S Electrical components and wiring

NOTE: If warning and safety labels are damaged, contact your

Polaris dealer for free replacement.

Grease all zerk fittings immediately after washing. Allow the engine to

run for a while to evaporate any water that may have entered the engine

or exhaust system.

Polishing the Vehicle

Polaris recommends the use of common household aerosol furniture

polish for polishing the finish on your Polaris vehicle. Follow the

instructions on the container.

Polishing Tips

S Avoid the use of automotive products, some of which can scratch the

finish of your vehicle.

S Always use clean cloths and pads for cleaning and polishing. Old or

reused cloths and pads may contain dirt particles that will scratch the

finish.

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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.

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. Never use

abrasive cleaners on plated or painted surfaces.

2. Rinse well with clear water. Soap, detergents, salt, dirt, mud and

other elements can cause corrosion.

3. Polish the clean chrome wheels periodically. Use an automotive

grade chrome polish.

4. Routinely and liberally apply a weather resistant wax to each

polished chrome wheel. Choose a product suitable for chrome

finishes. Read and follow the product labels and instructions.

Removing Corrosion

If light rust is found on the chrome finish, use steel wool (#0000--OTT

grade) to remove it. Gently rub the affected areas with the steel wool

until the corrosion has been removed. Clean and polish the wheel as

outlined above.

100

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MAINTENANCE

Cleaning and Storage

Storage Tips

See page 107 for the part numbers of Polaris products.

CAUTION

Starting the engine during the storage period will disturb the

protective film created by fogging and damage could occur. Never

start the engine during the storage period.

Clean the Exterior

Make any necessary repairs and clean the vehicle as recommended. See

page 98.

Fuel Stabilizer

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.

NOTE: Carbon Clean removes water from fuel systems, stabilizes

fuel and removes carbon deposits from pistons, rings, valves

and exhaust systems.

3. Allow the engine to run for 15--20 minutes to allow the stabilizer to

disperse through the fuel in the tank and carburetor.

4. Turn the fuel valve off.

5. Drain the carburetor bowl.

Oil and Filter

Change the oil and filter. See page 67.

Air Filter / Air Box

1. Inspect and clean (or replace) the pre-cleaner and air filter.

2. Clean the air box.

3. Drain the sediment tube.

Recoil Housing

Drain the recoil housing. See page 86.

101

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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 60.

S Transmission fluid

S Brake fluid (change every two years and any time the fluid looks

dark or contaminated)

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.

3. Pour 2-3 tablespoons (29-44 ml) of engine oil into the hole.

NOTE: Use a section of small hose and a small plastic squeeze bottle

filled with the pre-measured amount of oil.

4. Reinstall the spark plug. Torque to specification.

5. Apply dielectric grease to the inside of the spark plug cap.

Reinstall the cap.

6. Turn the engine over several times using the recoil starter. Oil will

be forced in and around the piston rings and ring lands, coating the

cylinder with a protective film of fresh oil.

7. Treat the fuel system with Polaris Carbon Clean. See page 101.

8. If Polaris fuel system additive is not used, the fuel tank, fuel lines,

and carburetor should be completely drained of gasoline.

9. To eliminate any fuel remaining in the carburetor, run the engine

until it stops.

102

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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 60.

Battery Storage

See pages 94-97 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.

NOTE: Do not use plastic or coated materials. They do not allow

enough ventilation to prevent condensation, and may promote

corrosion and oxidation.

Transporting the ATV

Follow these procedures when

transporting the vehicle.

1. Turn off the engine and

remove the key to prevent loss

during transporting.

2. Turn the fuel valve off.

3. Be sure the fuel cap, oil cap

and seat are installed correctly.

4. Always tie the frame of the

ATV to the transporting unit

securely using suitable straps

or rope.

5. Always place the transmission

in gear and lock the parking

brake.

103

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SPECIFICATIONS

2008 Trail Blazer 330

Capacities & Dimensions

Body Style

Gen III

Dry Weight

488 lbs. (221 kg)

305 lbs. (138 kg)

30 lbs. (14 kg)

60 lbs. (27 kg)

850 lbs.(386 kg)

Maximum Weight Capacity

Front Rack Capacity (Accessory)

Rear Rack Capacity (Accessory)

Hitch Towing Rating (Accessory)

Unbraked Trailer Towing Capacity* 1263 lbs. (573 kg)

Tongue Weight

Fuel Capacity

Transmission Oil Capacity

Engine Oil Capacity

85 lbs. (38.6 kg)

3.25 gal. (12.3 l)

11.3 oz. (33 ml)

1.9 qts. (1.8 l) (including oil cooler)

1.7 qts. (1.6 l) (at oil change)

Turn Radius

Ground Clearance

Length

Width

Height

83 in. (211 cm)

5.5 in. (14 cm)

75 in. (190.5 cm)

46 in. (117 cm)

48 in. (122 cm)

Wheel Base

Engine & Cooling

Engine Model Number / Type

Lubrication

ES-32PFE-103 / 4 Cycle, Single Cylinder

Wet Sump

Bore x Stroke

Displacement

Compression Ratio

Engine Cooling

Alternator Output (watts)

Carburetion

78.5 x 68

329cc

9.2:1

Air with fan assisted oil cooler

200w @5000 rpm

BST 34

Main Jet

122.5

Pilot Jet

42.5

Needle Jet

P-4 (829)

Pilot Air Jet

160

Pilot Screw

2.0 turns

Jet Needle

4HB48-3

Ignition

DC CDI

Timing

Spark Plug Type / Gap

30° ± 2° @ 5000 RPM

BKR6E / .036 in. (.9 mm)

* Based on EU Directive 76/432/EC

104

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SPECIFICATIONS

2008 Trail Blazer 330

Drive System

Drive System Type

Shift Type

Automatic Polaris Variable Transmission (PVT)

Side Lever (H-N-R)

3.05:1

Gear Reduction - Reverse

Gear Reduction - Forward

Final Drive (ratio)

Drive Chain

2.68:1

11/40 78P

520 O-Ring

Front Tires / Pressure

Rear Tires / Pressure

23 x 7-10 / 4 psi (27.6 KPa)

22 x 11-10 / 3 psi (20.7 KPa)

Suspension and Brakes

Front Suspension

Rear Suspension

MacPherson strut with 8.2 in. (21 cm) travel

Progressive Rate Swing Arm with 10.5 in. (27

cm) travel

Shock Adjustment

Front/Rear Brakes

Auxiliary Foot Brake

Parking Brake

CAM

Hydraulic disc

Hydraulic lock, all wheel

Features

Headlight

1 Single Beam, 55w

8.26w

Taillight

Brake Light

26.9w

Battery

12V 14 AH

Accessory

Standard

DC Plug-In (Rear)

DC Socket (Forward)

Electric Start

High Temp Indicator

Windshield

Standard

Accessory

Standard

Neutral Indicator

Reverse Indicator

Speedometer

Fuel Gauge

Standard

Accessory

Standard

Tool Kit

Standard

105

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SPECIFICATIONS

2008 Trail Blazer 330

Jetting Chart

Altitude

AMBIENT

TEMPERATURE

Below 40° F

(Below 5° C)

+40°F and above

(+5°C and above)

Meters

(Feet)

0-1800

(0-6000)

127.5

122.5

1800-3700

(6000-12000)

120

115

Clutching Chart

Altitude

Shift

Weight

Drive Clutch Driven Clutch

Helix/Spring

Setting

Spring

Meters

(Feet)

0-1800

(0-6000)

10RH

5630709

Blue/Green

7041157

Black

7041782

5131446

2--2

1800-3700

(6000-12000)

20-40

5631356

Blue/Green

7041157

Black

7041782

5131446

2--2

106

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POLARIS PRODUCTS

Part No.

Description

Engine Lubricant

2870791

2876244

2876245

Fogging Oil (12 oz. Aerosol)

PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt.)

PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal.)

Gearcase / Transmission Lubricants

Premium AGL Synthetic Gearcase Lube (qt.)

Premium AGL Synthetic Gearcase Lube (gal.)

Premium ATV Angle Drive Fluid (8 oz.)

Premium ATV Angle Drive Fluid (2.5 gal.)

Pump for Gallon Jug

2873602

2873603

2871653

2872276

2870465

2871654

2872277

Premium Demand Drive Hub Fluid (8 oz.)

Premium Demand Drive Hub Fluid (2.5 gal.)

Grease / Specialized Lubricants

Premium All Season Grease (3 oz. cartridge)

Premium All Season Grease (14 oz. cartridge)

Starter Drive Grease

Premium U-Joint Lube (3 oz.)

Premium U-Joint Lube (14 oz.)

Grease Gun Kit

Dielectric Grease (Nyogelt)

Chain Lube (6.25 oz. aerosol)

Chain Lube (16 oz. aerosol)

2871322

2871423

2871460

2871515

2871551

2871312

2871329

2872073

2872348

Additives / Miscellaneous

Carbon Clean Plus (12 oz.)

Fuel Stabilizer (16 oz.)

DOT 4 Brake Fluid

LOCTITE 565 Thread Sealant

Polaris Battery Tendert Charger

2871326

2870652

2872189

2871956

2859044

107

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TROUBLESHOOTING

Contact your Polaris dealer for service if you’re unable to identify

solutions using the following charts.

Drive Belt and Cover Problems

Possible Cause

Solution

Driving onto a pickup or Shift transmission to low range during loading of the ATV

tall trailer in high range

to prevent belt burning.

Starting out going up a

steep incline

When starting out on an incline, use low range or dis-

mount the ATV (after first applying the park brake) and

perform the K-turn as described on page 54.

Driving at low RPM or

low ground speed (at

Drive at a higher speed or use low range more frequently.

The use of low range is highly recommended for cooler

approximately 3-7 MPH) PVT operating temperatures and longer component life.

Insufficient warm-up of

Warm the engine at least 5 minutes. With the transmission

ATVs exposed to low am- in neutral, advance the throttle to about 1/8 throttle in

bient temperatures

short bursts, 5 to 7 times. The belt will become more flex-

ible and prevent belt burning.

Slow/easy clutch engage- Use the throttle quickly and effectively.

ment

Towing/pushing at low

RPM/low ground speed

Use low range only.

Utility use/plowing

Use low range only.

Stuck in mud or snow

Shift the transmission to low range, and carefully use fast,

aggressive throttle application to engage clutch.

WARNING: Excessive throttle may cause loss of control

and vehicle overturn.

Climbing over large

objects from a stopped

position

Shift the transmission to low range and carefully use fast,

brief, aggressive throttle application to engage clutch.

WARNING: Excessive throttle may cause loss of control

and vehicle overturn.

Belt slippage from water Shift the transmission to neutral. Using the throttle, vary

or snow ingestion into the the engine RPM from idle to full throttle. Repeat several

PVT system

times as required. During this procedure, the throttle

should not be held at the full position for more than 10

seconds. Clutch seals should be inspected for damage if

repeated leaking occurs.

Clutch malfunction

See your Polaris dealer.

Poor engine performance Check for fouled plugs or foreign material in gas tank,

fuel lines, or carburetor. See your dealer.

Slippage from failure to

warm up belt

Always warm up the belt by operating below 30 mph for

one mile (5 miles or more when temperature is below

freezing).

Wrong or missing belt

Improper break-in

Always use the recommended belt.

Always break in a new belt and/or clutch by avoiding

aggressive or high speed operation during the first two full

tanks of fuel.

108

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TROUBLESHOOTING

Engine Doesn’t Turn Over

Possible Cause

Solution

Tripped circuit breaker

Low battery voltage

Reset the breaker

Recharge battery to 12.8 VDC

Check all connections and tighten

Loose battery connections

Loose solenoid connections

Engine Turns Over, Fails to Start

Possible Cause

Solution

Out of fuel

Turn fuel valve to reserve, refuel

Inspect and clean or replace

Drain the fuel system and refuel

Turn the fuel valve on

Clogged fuel valve or filter

Water is present in fuel

Fuel valve is turned off

Old or non-recommended fuel

Fouled or defective spark plug(s)

No spark to spark plug

Crankcase filled with water or fuel

Overuse of choke

Replace with new fuel

Inspect plug(s), replace if necessary

Inspect plug(s), verify stop switch is on

Immediately see your Polaris dealer

Inspect, clean and/or replace spark plugs

Replace the filter

Clogged fuel filter

Low battery voltage

Recharge battery to 12.8 VDC

See your Polaris dealer

Mechanical failure

Engine Pings or Knocks

Possible Cause

Solution

Poor quality or low octane fuel

Incorrect ignition timing

Replace with recommended fuel

See your Polaris dealer

Set gap to specs or replace plugs

Incorrect spark plug gap or heat range

109

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TROUBLESHOOTING

Engine Backfires

Possible Cause

Solution

Weak spark from spark plugs

Incorrect spark plug gap or heat range

Old or non-recommended fuel

Incorrectly installed spark plug wires

Incorrect ignition timing

Inspect, clean and/or replace spark plugs

Set gap to specs or replace plugs

Replace with new fuel

See your Polaris dealer

Mechanical failure

Engine Runs Irregularly, Stalls or Misfires

Possible Weak Spark Cause

Fouled or defective spark plugs

Worn or defective spark plug wires

Incorrect spark plug gap or heat range

Loose ignition connections

Water present in fuel

Solution

Inspect, clean and/or replace spark plugs

See your Polaris dealer

Set gap to specs or replace plugs

Check all connections and tighten

Replace with new fuel

Low battery voltage

Recharge battery to 12.8 VDC

Inspect and replace

Kinked or plugged fuel vent line

Incorrect fuel

Replace with recommended fuel

Inspect and clean or replace

See your Polaris dealer

Clogged air filter

Reverse speed limiter malfunction

Electronic throttle control malfunction

Other mechanical failure

See your Polaris dealer

Possible Lean Fuel Mixture Cause Solution

Low or contaminated fuel

Low octane fuel

Add or change fuel, clean the fuel system

Replace with recommended fuel

Replace filter

Clogged fuel filter

Incorrect jetting

See your Polaris dealer

Possible Rich Fuel Mixture Cause Solution

Overuse of choke

Fuel is very high octane

Incorrect jetting

Inspect, clean and/or replace spark plugs

Replace with lower octane fuel

See your Polaris dealer

110

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TROUBLESHOOTING

Engine Stops or Loses Power

Possible Cause

Solution

Out of fuel

Turn fuel valve to reserve, refuel

Inspect and replace

Kinked or plugged fuel vent line

Water present in fuel

Replace with new fuel

Overuse of choke

Inspect, clean and/or replace spark plugs

See your Polaris dealer

Fouled or defective spark plugs

Worn or defective spark plug wires

Incorrect spark plug gap or heat range

Loose ignition connections

Low battery voltage

Set gap to specs or replace plugs

Check all connections and tighten

Recharge battery to 12.8 VDC

Replace with recommended fuel

Inspect and clean or replace

See your Polaris dealer

Incorrect fuel

Clogged air filter

Reverse speed limiter malfunction

Electronic throttle control malfunction

Other mechanical failure

See your Polaris dealer

111

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WARRANTY

LIMITED WARRANTY

Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED

WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects

in material or workmanship. Polaris also gives a one year limited warranty on the final drive

chain for failure due to defects. This warranty covers the parts and labor charges for repair

or replacement of defective parts which are covered by this warranty. This warranty begins

on the date of purchase. This warranty is transferrable to another consumer during the war-

ranty period through a Polaris dealer.

REGISTRATION

At the time of sale, the Warranty Registration Form must be completed by your dealer and

submitted to Polaris within ten days. Upon receipt of this registration, Polaris will record

the registration for warranty. No verification of registration will be sent to the purchaser as

the copy of the Warranty Registration Form will be the warranty entitlement. If you have

not signed the original registration and received the “customer copy”, please contact your

dealer immediately. NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS

YOUR ATV IS REGISTERED WITH POLARIS.

Initial dealer preparation and set-up of your ATV is very important in ensuring trouble-free

operation. Purchasing a machine in the crate or without proper dealer set-up will void your

warranty coverage.

WARRANTY COVERAGE AND EXCLUSIONS:

LIMITATIONS OF WARRANTIES AND REMEDIES

The Polaris limited warranty excludes any failures that are not caused by a defect in material

or workmanship. This warranty does not cover accidental damage, normal wear and tear,

abuse or improper handling. This warranty also does not cover any ATV that has been al-

tered structurally, modified, neglected, improperly maintained, used for racing, or used for

purposes other than for which it was manufactured, or for any damages which occur during

trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addi-

tion, this warranty does not cover physical damage to paint or finish, stress cracks, tearing

or puncturing of upholstery material, corrosion, or defects in parts, components or the ATV

due to fire, explosions or any other cause beyond Polaris’ control.

This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are

not compatible with the ATV. The exclusive remedy for breach of this warranty shall be, at

Polaris’ exclusive option, repair or replacement of any defective materials, or components

or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY

REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.

POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL,

CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER

ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CON-

TRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. Some states do not per-

mit theexclusion orlimitation ofincidental orconsequential damagesor implied warranties,

so the above limitations or exclusions may not apply to you if inconsistent with controlling

state law.

112

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WARRANTY

WARRANTY COVERAGE AND EXCLUSIONS:

LIMITATIONS OF WARRANTIES AND REMEDIES

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED

WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR

PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRAN-

TY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT

STATED IN THIS WARRANTY. Some states do not allow limitations on how long an im-

plied warranty lasts, so the above limitation may not apply to you if inconsistent with con-

trolling state law.

HOW TO OBTAIN WARRANTY SERVICE

If your ATV requires warranty service, you must take it to a Polaris dealer authorized to re-

pair Polaris ATVs. When requesting warranty service you must present your copy of the

Warranty Registration form to the dealer. (THE COST OF TRANSPORTATION TO AND

FROM THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests that you use your

original selling dealer; however, you may use any Polaris Servicing Dealer to perform war-

ranty service.

Please work with your dealer to resolve any warranty issues. Should your dealer require any

additional assistance they will contact the appropriate personnel at Polaris.

This warranty gives you specific legal rights, and you may also have other rights which vary

from state to state.

If any of the above terms are void because of state or federal law, all other warranty terms

will remain in effect.

Engine Oil

1. Mixing oil brands or using non-recommended oil may cause engine damage. We recom-

mend the use of Polaris engine oil.

2. Damage resulting from the use of non-recommended lubricants may not be covered by

warranty.

SPARK ARRESTOR

Polaris warrants that the spark arrestor in this vehicle will meet the efficiency requirements

of 43 CFR 8343.1(c) for at least 1000 hours whensubjected tonormal useand whenmainte-

nance and installation are in accordance with Polaris recommendations.

113

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WARRANTY

Exported Vehicles

EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-

RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD

OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCA-

TION.

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.

This policy does not apply to vehicles registered to government officials or military per-

sonnel on assignment outside the country of the selling dealer’s authorized location.

This policy does not apply to Safety Recalls.

How to Get Service

In the Country where your vehicle was purchased:

Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you

move or are traveling within the country where your vehicle was purchased, Warranty or

Service Bulletin repairs may be requested from any authorized Polaris dealer who sells

the same line as your vehicle.

Outside the Country where your vehicle was purchased:

If you are traveling temporarily outside the country where your vehicle was purchased,

you should take your vehicle to an authorized Polaris dealer. You must show the dealer

photo identification from the country of the selling dealer’s authorized location as proof

of residence. Upon residence verification, the servicing dealer will be authorized to per-

form the warranty repair.

If You Move:

If you move to another country, be sure to contact Polaris Customer Assistance and the

customs department of the destination country before you move. Vehicles importation

rules vary considerably from country to country. You may be required to present docu-

mentation of your move to Polaris Industries in order to continue your warranty cover-

age. You may also be required to obtain documentation from Polaris Industries in order

to register your vehicle in your new country.

How to Get Service

If Purchased From A Private Party:

If you purchase a Polaris product from a private citizen outside of the country in which

the vehicle was originally purchased, all warranty coverage will be denied.

Notice

If your vehicle is registered outside of the country where it was purchased, and you have

not followed the procedure set out above, your vehicle will no longer be eligible for war-

ranty or service bulletin coverage of any kind. (Vehicles registered to Government offi-

cials or military personnel on assignment outside of the country where the vehicle was

purchased will continue to be covered by the basic warranty.)

For questions call Polaris Customer Assistance:

United States: 1-888-704-5290

Canada: 1-204-925-7100

114

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WARRANTY

U.S.A. EPA Emissions Limited Warranty

This All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited

warranty is in addition to the Polaris standard limited warranty for this vehicle.

Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at the

time of initial sale with the requirements of 40 CFR 1051 and, (2) free from defects in

materials and workmanship that may keep it from meeting these requirements.

The emissions warranty period for this vehicle begins on the date the vehicle is delivered

to the original retail purchaser and ends 30 months (2.5 years) after that date, after 5000

km (3100 miles), or after 500 hours of operation, whichever comes first.

This emission-related warranty covers components whose failure would increase an en-

gine’s emissions, including electronic controls, fuel injection, exhaust-gas recirculation,

aftertreatment, or any other system utilized in this vehicle to control emissions. Replac-

ing or repairing other components not covered by this emissions warranty or the standard

warranty is the responsibility of the owner; including the parts, labor and other costs

associated with recommended maintenance.

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.

POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL,

CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION,WHETHER

ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CON-

TRACT, NEGLIGENCE OR OTHER TORT OR OTHERWISE.

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY IM-

PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICU-

LAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY PERIOD

DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS WARRANTIES

NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how

long an implied warranty lasts, so the above limitation may not apply if it is inconsistent

with the controlling state law.

This limited warranty excludes failures not caused by a defect in material or workman-

ship. This limited warranty does not cover damage due to accidents, abuse or improper

handling, maintenance or use. This limited warranty also does not cover any engine that

has been structurally altered, or any engine that has been used in racing competition. This

limited warranty also does not cover physical damage, corrosion or defects caused by

fire, explosions or other similar causes beyond the control of Polaris.

If you have any questions regarding your warranty rights and responsibilities, you

should contact the Polaris Warranty Department at 1-888-704-5290.

115

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MAINTENANCE LOG

Use the following chart to record periodic maintenance.

DATE

MILES (KM)

TECHNICIAN

SERVICE PERFORMED / COMMENTS

116

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MAINTENANCE LOG

DATE

MILES (KM)

TECHNICIAN

SERVICE PERFORMED / COMMENTS

117

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INDEX

Age Restrictions . . . . . . . . . . . . . . . .

Air Filter . . . . . . . . . . . . . . . . . . . . . 84

Auxiliary Brake . . . . . . . . . . . . 37, 72

Electrical Switches . . . . . . . . . . . . . 31

Emissions Warranty . . . . . . . . . . . 115

Engine Break-in . . . . . . . . . . . . . . . 41

Engine Fogging . . . . . . . . . . . . . . 102

Equipment Modifications . . . . . . . . 10

Exhaust Emission Control System . 59

Battery . . . . . . . . . . . . . . . . . . . . 91-97

Battery Charging (Conventional) . . 95

Battery Charging (Sealed) . . . . . . 96-97

Battery Fluid (Conventional) . . . . . 95

Battery Installation . . . . . . . . . . . . . 93

Battery Removal . . . . . . . . . . . . . . . 92

Battery Storage . . . . . . . . . . . . . . . . 94

Belt Break-in . . . . . . . . . . . . . . . . . . 41

Brake Lever . . . . . . . . . . . . . . . . . . 34

Brake, Auxiliary . . . . . . . . . . . . . . . 72

Brakes . . . . . . . . . . . . . . . . . . 35, 71-72

Break-In Period . . . . . . . . . . . . . . . . 41

Front Wheel Hub Tightening . . . . . 78

Fuel Filter . . . . . . . . . . . . . . . . . . . . 38

Fuel Safety . . . . . . . . . . . . . . . . . . . 26

Fuel Stabilizer . . . . . . . . . . . . . . . . 101

Fuel Tank . . . . . . . . . . . . . . . . . . . . 38

Fuel Valve . . . . . . . . . . . . . . . . . . . . 38

Gear Selector . . . . . . . . . . . . . . . . . . 39

Camber and Caster . . . . . . . . . . . . . 72

Carburetor . . . . . . . . . . . . . . . . . . . . 75

Choke . . . . . . . . . . . . . . . . . . . . . . . 38

Chrome Wheel Care . . . . . . . . . . . 100

Cleaning and Storage . . . . . . . . 98-103

Clutch Break-in . . . . . . . . . . . . . . . . 41

Crankcase Emission Control System 59

Handlebars . . . . . . . . . . . . . . . . . . . 74

Hauling Cargo . . . . . . . . . . . . . . . 46-47

Headlight Lamp Replacement . . . . . 82

Indicator Lamp Replacement . . . . . 83

Indicator Lights . . . . . . . . . . . . . . . . 32

Drive Chain . . . . . . . . . . . . . . . . 79-81

Drivetrain Break-in . . . . . . . . . . . . . 41

Driving Downhill . . . . . . . . . . . . . . 52

Driving in Reverse . . . . . . . . . . . . . 57

Driving on Slippery Surfaces . . . . . 49

Driving Over Obstacles . . . . . . . . . . 56

Driving Procedures . . . . . . . . . . . . . 45

Driving Safely . . . . . . . . . . . . . . . 45-58

Driving Through Water . . . . . . . . . . 55

Driving Uphill . . . . . . . . . . . . . . 50-51

K-turn . . . . . . . . . . . . . . . . . . . . . . . 54

Light Switches . . . . . . . . . . . . . . . . 32

Lights . . . . . . . . . . . . . . . . . . . . . 82-83

Lubrication Recommendations . . 64-65

Main Switch . . . . . . . . . . . . . . . . . . 31

Making Turns . . . . . . . . . . . . . . . . . 48

118

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INDEX

Noise Emission Control System . . . 59

Safe Riding Gear . . . . . . . . . . . . . . . 30

Safety Decals and Locations . . . . 27-29

Safety Training . . . . . . . . . . . . . . . . .

Oil Change . . . . . . . . . . . . . . . . . . . 67

Oil Check . . . . . . . . . . . . . . . . . . . . 66

Oil Recommendations . . . . . . . . . . . 66

Oil, Engine . . . . . . . . . . . . . . . . . 66-67

Oil, Transmission . . . . . . . . . . . . 68-69

Operator Safety . . . . . . . . . . . . . . . 6-25

Override Switch . . . . . . . . . . . . . . . 31

Sidehilling . . . . . . . . . . . . . . . . . . . 53

Spark Arrestor . . . . . . . . . . . . . . . . . 90

Spark Plugs . . . . . . . . . . . . . . . . . 85-86

Specifications . . . . . . . . . . . . . 104-106

Starting the Engine . . . . . . . . . . . 43-44

Steering Assembly . . . . . . . . . . . . . 72

Stop Switch . . . . . . . . . . . . . . . . . . . 31

Storage Tips . . . . . . . . . . . . . . 101-103

Parking Brake . . . . . . . . . . . . . . . . . 36

Parking on an Incline . . . . . . . . . . . 58

Periodic Maintenance Chart . . . . 60-63

Polaris Products . . . . . . . . . . . . . . 107

Pre Ride Inspection . . . . . . . . . . . . . 42

PVT Break-in . . . . . . . . . . . . . . . . . 41

PVT Drying . . . . . . . . . . . . . . . . . . 89

PVT System . . . . . . . . . . . . . . . . 88-89

Taillight/Brakelight Lamp

Replacement . . . . . . . . . . . . . . 83

Throttle Cable Freeplay . . . . . . . . . . 73

Throttle Lever . . . . . . . . . . . . . . . . . 33

Tire Tread Depth . . . . . . . . . . . . . . . 78

Toe Alignment . . . . . . . . . . . . . . . . 70

Towing Capacities . . . . . . . . . . . . . . 46

Transmission Gear Selector . . . . . . . 39

Transmission Oil . . . . . . . . . . . . . . . 68

Transmission Oil Change . . . . . . . . 69

Transmission Oil Check . . . . . . . . . 68

Transporting the ATV . . . . . . . . . . 103

Turning Around on a Hill . . . . . . . . 54

Rear Drive Chain Slack . . . . . . . . 80-81

Rear Spring . . . . . . . . . . . . . . . . . . . 72

Recoil Housing . . . . . . . . . . . . . . . . 86

Recoil Starter . . . . . . . . . . . . . . . . . 40

Vehicle Identification Numbers . . . . .

Vehicle Immersion . . . . . . . . . . . . . 87

Washing the Vehicle . . . . . . . . . . 98-99

Wheel Installation . . . . . . . . . . . . . . 77

Wheel Nut Torque Specifications . . 77

Wheel Removal . . . . . . . . . . . . . . . 76

Wheels . . . . . . . . . . . . . . . . . . . . 76-78

119

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