Polaris Offroad Vehicle 4X4 International User Manual

Download from Www.Somanuals.com. All Manuals Search And Download.  
The text is printed on 100% recycled  
with 40% post-consumer waste (PCW).  
Download from Www.Somanuals.com. All Manuals Search And Download.  
WELCOME  
Thank you for purchasing a Polaris vehicle, and welcome to our world-  
wide family of Polaris owners. We proudly produce an exciting line of  
utility and recreational products.  
• Snowmobiles  
• All-terrain vehicles (ATVs)  
®
RANGER utility vehicles  
®
• Victory Motorcycles  
Always follow the instructions and recommendations in this manual.  
The manual contains instructions for minor maintenance, but informa-  
tion about major repairs is outlined in the Polaris Service Manual and  
®
should be performed only by a factory-certified Master Service Dealer  
(MSD) technician. Please see your dealer for all of your service needs  
during (and after) the warranty period.  
For more information about Polaris, visit us online at  
www.polarisindustries.com.  
1
Download from Www.Somanuals.com. All Manuals Search And Download.  
POLARIS, THE WAY OUT and SCRAMBLER are registered trademarks of Polaris  
Industries Inc.  
Copyright 2009 Polaris Sales Inc. All information contained within this publication is  
based on the latest product information at the time of publication. Due to constant  
improvements in the design and quality of production components, some minor discrep-  
ancies may result between the actual vehicle and the information presented in this publi-  
cation. 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.  
2010 Scrambler 4X4 International Owner’s Manual  
P/N 9922463  
2
Download from Www.Somanuals.com. All Manuals Search And Download.  
TABLE OF CONTENTS  
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  
Features and Controls . . . . . . . . . . . . . . . . . . . 20  
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29  
Emission Control Systems . . . . . . . . . . . . . . . 46  
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 47  
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . . 99  
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 100  
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 104  
Declaration of Conformity. . . . . . . . . . . . . . . 106  
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107  
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 111  
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113  
3
Download from Www.Somanuals.com. All Manuals Search And Download.  
INTRODUCTION  
The following signal words and symbols appear throughout this manual  
and on your vehicle. Your safety is involved when these words and sym-  
bols are used. Become familiar with their meanings before reading the  
manual.  
The safety alert symbol indicates a potential personal injury hazard.  
WARNING  
A WARNING indicates a hazardous situation which, if not avoided, may result in  
death or serious injury.  
CAUTION  
A CAUTION indicates a hazardous situation which, if not avoided, may result in  
minor or moderate injury.  
NOTICE  
A NOTICE indicates a situation that may result in property damage.  
The Prohibition Safety Sign indicates an action NOT to take in order  
to avoid a hazard.  
The Mandatory Action Sign indicates an action that NEEDS to be  
taken to avoid a hazard.  
4
Download from Www.Somanuals.com. All Manuals Search And Download.  
INTRODUCTION  
WARNING  
Failure to follow the warnings in this manual can result in serious injury or death.  
This Polaris vehicle is not a toy and can be hazardous to operate. A collision or  
rollover can occur quickly, even during routine maneuvers, if you fail to take  
proper precautions.  
Read and understand your owner's manual and all warnings before operating  
this Polaris vehicle.  
Safety Training  
When you purchased your new Polaris vehicle, your dealer offered a  
hands-on safety training course. You were also provided with printed  
materials that explain safe operating procedures. Review this informa-  
tion on a regular basis.  
If you purchased a used Polaris vehicle from a party other than a Polaris  
dealer, please request free safety training from any authorized Polaris  
dealer.  
Age Restrictions  
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited  
for anyone under 16 years of age.  
Restrictions  
This vehicle is approved for OFF-ROAD TOWING ONLY. Towing a  
trailer with this vehicle on public roads is prohibited.  
Equipment Modifications  
The warranty on your Polaris vehicle may be terminated if any equip-  
ment has been added, or if any modifications have been made, that  
increase speed or power. The addition of certain accessories, including  
(but not limited to) mowers, blades, tires, sprayers and large racks may  
change vehicle handling. Use only Polaris-approved accessories. Know  
their function and effect on the vehicle.  
5
Download from Www.Somanuals.com. All Manuals Search And Download.  
INTRODUCTION  
Vehicle Identification Numbers  
Record your vehicle's identification numbers and key number in the  
spaces provided. Remove the spare key and store it in a safe place. An  
ignition key can be duplicated only by ordering a Polaris key blank  
(using your key number) and mating it with one of your existing keys.  
The ignition switch must be replaced if all keys are lost.  
VIN  
####  
Key Number  
Vehicle Model Number: ___________________________________________________  
Frame VIN: ____________________________________________________________  
Engine Serial Number: ___________________________________________________  
(right front side of engine crankcase)  
Key Number: ___________________________________________________________  
6
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
WARNING  
Failure to operate the vehicle properly can result in a collision, loss of control,  
accident or overturn, which may result in serious injury or death. Heed all safety  
warnings outlined in this section of the owner’s manual. See the OPERATION  
section of the owner’s manual for proper operating procedures.  
Equipment Modifications  
We strongly recommend that consumers do not install on a Polaris vehi-  
cle any equipment that may increase the speed or power of the vehicle,  
or make any other modifications to the vehicle for these purposes.  
The warranty on your Polaris vehicle is terminated if any equipment has  
been added to the vehicle, or if any modifications have been made to the  
vehicle, that increase its speed or power.  
The addition of certain accessories, including (but not limited to) mow-  
ers, blades, tires, sprayers, or large racks, may change the handling char-  
acteristics of the vehicle. Use only Polaris-approved accessories, and  
familiarize yourself with their function and effect on the vehicle.  
7
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Safe Riding Gear  
Always wear appropriate clothing when riding a Polaris vehicle. Wear  
protective clothing for comfort and to reduce the chance of injury.  
Eye Protection  
Long  
Sleeves  
Helmet  
Gloves  
Long Pants  
Boots  
Helmet  
Wearing a helmet can prevent a severe head injury. Whenever riding a  
Polaris vehicle, always wear a helmet that meets or exceeds established  
safety standards.  
Approved helmets in the USA and Canada bear a U.S. Department of  
Transportation (DOT) label.  
Approved helmets in Europe, Asia and Oceania  
bear the ECE 22.05 label. The ECE mark consists  
4
E
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 displayed on the label.  
051039  
0006.31  
8
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Safe Riding Gear  
Eye Protection  
Do not depend on eyeglasses or sunglasses for eye protection. When-  
ever riding a Polaris vehicle, always wear shatterproof goggles or use a  
shatterproof helmet face shield. Polaris recommends wearing approved  
Personal Protective Equipment (PPE) bearing markings such as VESC  
8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.  
Gloves  
Off-road style gloves with knuckle pads are the best for comfort and  
protection.  
Boots  
The best footwear is a pair of sturdy over-the-calf boots with low heels.  
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.  
9
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Read and understand all warnings, cautions  
and operating procedures in this manual and  
on the safety labels before operating the  
vehicle.  
Never operate this vehicle without proper  
instruction. Take a training course. Beginners  
should receive training from a certified  
instructor. Contact an authorized Polaris  
dealer or visit the Polaris web site at  
www.polarisindustries.com.  
Never permit others to operate the vehicle unless they have read and under-  
stand this manual and all product labels, and have completed a certified safety  
training course.  
Never allow anyone under 16 years of age to  
operate this vehicle.  
Never carry a passenger.  
10  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Always wear an approved helmet that fits  
properly. Wear eye protection (goggles or face  
shield), gloves, boots, long sleeves and long  
pants.  
Never consume alcohol or drugs before or while  
operating this vehicle.  
Never operate at excessive speeds. Travel  
and turn at speeds appropriate for the terrain,  
visibility, operating conditions and your  
experience.  
Never attempt jumps or other stunts.  
11  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Always inspect your Polaris vehicle before each  
use to verify that it's in safe operating condition.  
Follow the inspection and maintenance procedures  
outlined in this manual. See page 30.  
Keep both hands on the handlebars. Keep  
your feet on the footrests.  
Always travel slowly when operating on  
unfamiliar terrain. Use extra caution.  
Use caution when operating on rough, slippery  
or loose terrain.  
Always follow the procedures outlined in this  
manual for turning. See page 34.  
Never turn sharply at excessive speeds,  
which can lead to vehicle overturn.  
12  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
If the vehicle has been involved in an accident, always have an authorized  
Polaris dealer inspect the entire vehicle for possible damage, including (but not  
limited to) brake, throttle and steering systems.  
Never operate on hills too steep for the vehicle or  
for your abilities. Practice on smaller hills before  
attempting larger hills. Avoid climbing hills steeper  
than 25°.  
Always follow the procedures outlined in this  
manual for climbing hills. See page 36.  
+25°  
Always follow the procedures outlined in this  
manual for driving downhill and for braking on  
hills. See page 38.  
Always follow the procedures outlined in this  
manual for crossing the side of a hill. See page  
37.  
Never attempt to turn the vehicle around on any  
hill until you've mastered (on level ground) the  
turning technique outlined in this manual.  
Always follow the procedures outlined in this  
manual for braking if you stall or roll backwards  
while climbing a hill. Never back down a hill. See  
page 39.  
13  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Always follow the procedures outlined in this manual for operating over  
obstacles. See page 41.  
Always follow the procedures outlined in this manual for operating on slippery or  
loose surfaces. Use extra caution. Always avoid skidding or sliding. See page  
35.  
Always follow the procedures outlined in this  
manual for driving through water. Never drive  
through deep or fast-flowing water. See page 40.  
Always follow the procedures outlined in this manual for driving in reverse. See  
page 42.  
Always use the size and type of tires specified for  
your vehicle. Maintain the proper tire pressure.  
Never modify this Polaris vehicle  
through improper installation or use of  
accessories.  
Operating on paved surfaces may affect the handling and control of the vehicle  
and could result in loss of control. Avoid sudden turns or swift movement of the  
handlebars.  
14  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Never exceed the stated load capacity for your vehicle. Cargo must be properly  
distributed and securely attached. Reduce speed and follow the instructions in  
this manual for carrying cargo or towing. Allow a greater distance for braking.  
Never operate this vehicle on a frozen body of water.  
Always remove the ignition key when the vehicle is not in use to prevent  
unauthorized use or accidental starting.  
Always unlock the steering before starting the engine. See page 27.  
Handling Gasoline  
Gasoline is highly flammable and explosive under certain conditions.  
• Always exercise extreme caution whenever handling gasoline.  
• Always refuel with the engine stopped, and outdoors or in a well ventilated  
area.  
• Do not smoke or allow open flames or sparks in or near the area where refu-  
eling is performed or where gasoline is stored.  
• Do not overfill the tank. Do not fill the tank neck.  
• If gasoline spills on your skin or clothing, immediately wash it off with soap  
and water and change clothing.  
• Turn the fuel valve off whenever the vehicle is stored or parked.  
Hot components can cause serious burns and fire. Do not touch hot exhaust  
system components. Always keep combustible materials away from the exhaust  
system.  
For more information about safety, contact an authorized  
Polaris dealer or visit the Polaris web site at  
www.polarisindustries.com.  
15  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Safety Labels and Locations  
Warning labels have been placed on the vehicle for your protection.  
Read and follow the instructions on each label carefully. If any of the  
labels shown in this manual differ from the labels on your vehicle,  
always read and follow the instructions of the labels on the vehicle.  
If an informational or graphic label becomes illegible or comes off, con-  
tact your Polaris dealer to purchase a replacement. Replacement safety  
labels are provided by Polaris at no charge. The part number is printed  
on the label.  
General Warning  
WARNING  
Improper ATV use can result in SEVERE INJURY or DEATH  
ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR  
NEVER USE ON PUBLIC ROADS  
NEVER CARRY PASSENGERS  
NEVER USE WITH DRUGS OR ALCOHOL  
NEVER operate:  
• without proper training or instruction  
• at speeds too fast for your skills or the conditions  
• on public roads - a collision can occur with another vehicle  
• with a passenger - passengers affect balance and steering and increase risk  
of losing control  
ALWAYS:  
• use proper riding techniques to avoid vehicle overturns on hills and rough ter-  
rain and in turns  
• avoid paved surfaces - pavement may seriously affect handling and control  
LOCATE AND READ OWNER’S MANUAL.  
FOLLOW ALL INSTRUCTIONS AND WARNINGS.  
7175376  
16  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Safety Labels and Locations  
General  
Warning  
+
+
Discretionary  
Warning  
Discretionary Warning  
WARNING  
• Never operate this ATV on HILLS steeper than 25 degrees  
25°. To pre-  
vent overturn on hilly terrain, use throttle and brakes gradually, and shift  
weight uphill.  
• REVERSE operation can be dangerous even at low speeds. Steering  
becomes difficult. To prevent loss of control, avoid sudden braking or sharp  
turns.  
7175511  
17  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Safety Labels and Locations  
Tire Pressure/Load  
Warning  
“No Passenger”  
Warning  
Age 16 Warning  
+
+
+
+
Clutch Cover  
Warning  
“No Passenger” Warning  
WARNING  
NEVER ride as a passenger.  
Passengers can cause a loss of control, resulting in SEVERE INJURY or  
DEATH.  
7175378  
Tire Pressure/Load Warning  
WARNING  
Improper tire pressure or overloading can cause loss of control.  
Loss of control can result in severe injury or death.  
• Cold tire pressure:  
Front: 4.0 psi (27.6 kPa)  
Rear: 3.0 psi (20.7 kPa)  
• Maximum weight capacity: 275 lbs. (125 kg)  
7175443  
18  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Safety Labels and Locations  
Age 16 Warning  
WARNING  
Operating this ATV if you are under the age of 16 increases your chance of  
severe injury or death.  
NEVER operate this ATV if you are under age 16.  
7175374  
Clutch Cover Warning  
WARNING  
• Moving parts hazard under belt-clutch guard. To prevent serious injury, do not  
operate vehicle with guard removed.  
• Do not modify engine or clutch. Doing so can cause part failure, possible  
imbalance, and excessive engine RPM, which can result in serious injury or  
death.  
NO STEP  
7172563  
Reverse Override Warning  
WARNING  
Improper use of override button can lead to loss of control resulting in severe  
injury or death. Do not activate override while throttle is engaged. Always apply  
throttle gradually, while in reverse.  
7175486  
4X4 Caution  
CAUTION  
Do not push switch to engage 4X4 (AWD) if the rear wheels are spinning. This  
may cause severe drive shaft and clutch damage.  
7175485  
19  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FEATURES AND CONTROLS  
Switches  
Engine Stop Switch  
The engine will not start  
or run when the switch is  
in the OFF position.  
Headlight  
Switch  
OFF  
Engine  
Stop  
RUN  
Switch  
Push the stop switch  
down to stop the engine  
quickly. Pull the stop  
switch up to the RUN  
position before attempt-  
ing to start the engine.  
Override  
Switch  
Hazard  
Switch  
Horn  
Switch  
Both the main switch and  
the engine stop switch  
will shut off all electrical power to the vehicle, including lights.  
Override Switch  
This vehicle is equipped with a reverse speed limiter system. To gain  
additional wheel speed while backing, release the throttle and press the  
override switch.  
Pressing the override switch while the throttle is open can cause loss of control,  
which may result in serious injury or death. Always release the throttle before  
pressing the override switch.  
The override switch also allows activation of All Wheel Drive in  
reverse, if the AWD switch is on.  
20  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FEATURES AND CONTROLS  
Switches  
Headlight Switch  
The lights do not operate unless the main key switch is on and the  
engine stop switch is in the RUN position.  
High Beam  
Low Beam  
Turn Signal Switch  
Push the toggle switch either left or right to activate the corre-  
sponding turn signal light. The indicator on the pod will also  
flash. Return the toggle to the center position and push it inward  
to end the signal.  
Hazard Switch  
Push the hazard warning switch to cause all turn signal lights to  
flash simultaneously. Use this feature to alert others of an emer-  
gency or other situation requiring caution.  
Horn Switch  
Press the horn switch to sound the horn.  
Main Key Switch  
Use the main key switch to start the engine. See page 31 for starting pro-  
cedures.  
All Wheel Drive Switch  
See page 28 for all wheel drive information.  
Main Key Switch  
All Wheel Drive  
Switch  
21  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FEATURES AND CONTROLS  
Mirrors  
Use the mirrors to assist in traffic maneuvers. Always check and adjust  
the mirrors before driving the vehicle.  
Indicator Lights  
With the engine running, verify the function of all indicator lights before  
each use of the vehicle.  
Tip: The taillight is on whenever the main switch (key) is on. Turn the key off to  
prevent battery drain.  
Reverse  
Indicator  
Turn Signal/Hazard Indicators  
High Beam Indicator  
Neutral Indicator  
High Temperature Warning  
(displays if engine overheats)  
22  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FEATURES AND CONTROLS  
Throttle Lever  
Press the throttle lever to  
increase engine speed and  
vehicle movement. Release the  
lever to reduce engine speed  
and vehicle movement.  
Failure to check or maintain proper operation of the throttle system can result in  
an accident if the throttle lever sticks during operation. Check the lever for  
proper operation before starting the engine. Check occasionally during  
operation.  
Do not start or operate a vehicle with sticking or improperly operating throttle  
controls. Contact your dealer for repair if throttle problems arise.  
Electronic Throttle Control (ETC)  
ETC causes the engine to  
Electronic Throttle Control  
stop if the throttle cable  
sticks in an open position  
when the operator releases  
the throttle lever.  
The Electronic Throttle Control (ETC) stops the engine in the event of a throttle  
system malfunction. Do not modify the ETC system or replace it with other  
throttle mechanisms.  
23  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FEATURES AND CONTROLS  
Brakes  
Aggressively applying the brakes when backing down a hill may cause rear  
tipover. Aggressively applying the brakes while moving forward may cause the  
rear wheels to skid and result in loss of control.  
Read this owner's manual and understand the operation of all brake systems on  
this vehicle. Always use caution whenever applying the brakes.  
Foot Brake  
The all-wheel foot brake is located  
on the right footrest. The foot brake  
operates both front and rear brakes.  
Press the brake pedal down with  
your foot to apply the all-wheel  
brakes.  
If the rear wheels begin to skid or  
slide while using the foot brake,  
reduce brake pressure.  
Foot Brake  
Hand Brake Lever  
The hand brake operates both  
front and rear brakes. Squeeze  
the brake lever toward the han-  
dlebar to apply the all-wheel  
brakes.  
If the rear wheels begin to skid  
or slide while using the hand  
brake, reduce lever pressure.  
Operating the vehicle with a spongy brake lever can result in loss of braking,  
which could cause an accident. Never operate the vehicle with a spongy-feeling  
brake lever. Always contact your dealer for service before operating the vehicle.  
24  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FEATURES AND CONTROLS  
Brakes  
Parking Brake  
Locking the Parking Brake  
1. Place the transmission in gear.  
2. Squeeze and release the brake  
lever two or three times, then  
squeeze and hold.  
3. Push the parking brake lock  
forward to engage the lock.  
4. Release the brake lever.  
5. To release the parking brake  
lock, squeeze and release the brake lever. It will return to its  
unlocked position.  
Operating the vehicle while the parking brake is engaged could result in an  
accident and serious injury or death. Always release the parking brake lock  
before operating.  
Transmission Gear Selector  
The transmission gear selector is located  
on the right side of the vehicle.  
F: Forward Gear  
N: Neutral  
R: Reverse  
Gear  
Selector  
To shift gears, brake to a complete stop.  
When the engine is idling, move the lever  
to the desired gear.  
NOTICE: Shifting gears with the engine  
speed above idle or while the  
vehicle is moving could cause  
transmission damage.  
Whenever the vehicle is left unattended,  
always place the transmission in gear and  
lock the parking brake.  
25  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FEATURES AND CONTROLS  
Choke  
The choke assists in starting a cold  
engine. Refer to the engine start-  
ing procedure on page 31 for cor-  
rect choke and throttle settings  
during starting.  
Fuel  
Guage  
Fuel Tank Cap  
Choke  
Always refuel with the engine  
stopped, and outdoors or in a well  
ventilated area. Refuel on a level  
surface.  
Fuel Tank  
Cap  
Remove the fuel tank cap to add  
fuel to the fuel tank. Use either  
leaded or unleaded gasoline with a  
minimum pump octane number of  
87=(R+ M/2) octane. Do not use  
fuel with ethanol content greater  
than 10 percent, such as E-85 fuel.  
Fuel Valve  
The fuel valve is located on the  
left side of the vehicle, below the  
fender.  
ON: For normal operation.  
Fuel  
Valve  
OFF: For vehicle storage and  
when transporting.  
Fuel Filter  
The in-line fuel filter should be  
replaced by your dealer after  
every 100 hours of operation or  
ON  
OFF  
annually. Do not attempt to clean the fuel filter.  
26  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FEATURES AND CONTROLS  
Steering Lock  
Lock the steering to prevent  
unauthorized use or theft of  
the vehicle.  
Tip: Place the steering lock  
keys in a safe place. The  
lock must be replaced if the keys are lost.  
1. Turn the handlebars to the full left posi-  
tion.  
2. Insert the steering lock key and turn it  
clockwise. Remove the key.  
3. Reverse the procedure to unlock the  
steering.  
The handlebars are locked in the full left position when the steering is locked.  
Always unlock the steering before starting the engine.  
27  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FEATURES AND CONTROLS  
All Wheel Drive (AWD) System  
The AWD switch may be turned on or off while the vehicle is moving.  
AWD will not engage until engine speed is below 3100 RPM. AWD  
remains engaged until the switch is turned off. There is no limit to the  
length of time the vehicle may remain in AWD.  
If the switch is turned off while the demand drive unit is engaged, it will  
not disengage until the rear wheels regain traction. Engage AWD before  
getting into situations where maximum traction is needed. If the rear  
wheels are spinning, release the throttle before switching to AWD.  
Tip: The override switch allows activation of AWD in reverse if the AWD switch  
is on.  
Switching to AWD while the rear wheels are spinning may cause severe drive  
shaft and gearcase damage. Always switch to AWD while the rear wheels have  
traction or are at rest.  
AWD  
When the AWD switch is on,  
the vehicle is in four-wheel  
drive and the differential is  
locked, providing maximum  
traction. The demand drive  
unit automatically engages  
when the rear wheels lose trac-  
tion. When the rear wheels  
regain traction, the demand drive unit automatically disengages.  
2X4  
When the 2X4 switch is on,  
the vehicle is in two-wheel  
drive at all times and the dif-  
ferential is locked.  
28  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Break-In Period  
The break-in period for your new Polaris vehicle is the first ten hours of  
operation, or the time it takes to use the first two full tanks of gasoline.  
No single action on your part will increase the life and performance of  
your vehicle more than following the procedures for a proper break-in.  
Careful treatment of a new engine and drive components will result in  
more efficient performance and longer life for these components.  
Do not operate at full throttle or high speeds for extended periods during  
the first three hours of use.  
Engine and Drivetrain Break-in  
1. Fill the fuel tank with gasoline. See page 26.  
2. Check the oil level. Add oil if necessary.  
3. Select an open area that allows room to familiarize yourself with  
vehicle operation and handling.  
4. Drive slowly. Vary the 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 30.  
6. Pull only light loads.  
7. Change both the oil and the filter at 20 hours or one month.  
PVT Break-in (Clutches/Belt)  
Break in the clutches and belt by operating at slower speeds during the  
break-in period as recommended. Pull only light loads. Avoid aggres-  
sive acceleration and high speed operation during the break-in period.  
29  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Pre-Ride Checklist  
Failure to inspect and verify that the vehicle is in safe operating condi-  
tion before operating increases the risk of an accident. Always inspect  
the vehicle before each use to make sure it's in safe operating condition.  
Item  
Remarks  
Page  
Hand brake  
Brake fluid  
Foot brake  
Ensure proper operation  
Ensure proper level  
24  
59  
24  
51  
51  
27  
Ensure proper operation  
Inspect, lubricate if necessary  
Inspect, lubricate if necessary  
Front suspension  
Rear suspension  
Steering/steering lock  
Unlock the steering; ensure free  
operation  
Tires  
Inspect condition and pressure  
65  
65  
-
Wheels/fasteners  
Inspect, ensure fastener tightness  
Frame nuts, bolts, fasteners Inspect, ensure tightness  
Fuel and oil  
Ensure proper levels  
26  
52  
Coolant level  
Coolant hoses  
Throttle  
Ensure proper level  
Inspect for leaks  
74  
-
Ensure proper operation  
23  
64  
Indicator lights/switches  
Engine stop switch  
Mirrors  
Ensure operation  
20  
20  
22  
71  
Ensure proper operation  
Adjust for best side/rear vision  
Drive chain  
Check condition/slack, lubricate as  
needed  
Air filter, pre-filter  
Air box sediment tube  
Headlamp  
Inspect, clean  
68  
-
Drain deposits whenever visible  
Check operation, apply Polaris dielec-  
tric grease when lamp is replaced  
21  
77  
Brake light/taillight  
Riding gear  
Check operation, apply Polaris dielec-  
tric grease when lamp is replaced  
78  
Wear approved helmet, goggles, and  
protective clothing  
8
30  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Starting the Engine  
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.  
Tip: The starter interlock will prevent the engine from starting if the transmission  
is in gear and the brake is not engaged.  
4. Turn the fuel valve on.  
5. Sit on the vehicle.  
Tip: 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. If  
the knob doesn't stay where  
positioned, increase the ten-  
sion by rotating the tension  
adjusting nut clockwise.  
Tip: The variable choke is fully on when  
Choke  
Knob  
the knob is pulled completely out.  
The choke is off when the knob is  
pushed completely in. The choke  
can be adjusted gradually, depend-  
ing 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 compo-  
nents.  
Adjusting  
Nut  
7. Pull the engine stop switch up to RUN.  
31  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Starting the Engine  
8. Do not press the throttle while starting the engine. 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 starter and wait five seconds.  
10. Repeat steps 8 and 9 until the engine starts.  
Operating the vehicle immediately after starting could cause engine damage.  
Allow the engine to warm up for several minutes before operating the vehicle.  
11. If a warm engine has cooled to a point where it does not readily  
start, intermittent use of the choke (knob 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.  
12. If the engine slows or stops, 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.  
32  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Driving Procedures  
1. Wear a helmet and eye protection. See page 8.  
2. Sit upright. Keep your feet on the footrests. Keep both hands on the  
handlebars.  
3. Start the engine and allow it to warm up.  
4. Shift the transmission into gear.  
5. Check your surroundings and determine your path of travel.  
6. Release the parking brake.  
7. Slowly squeeze the throttle lever toward the handlebar to begin  
driving.  
8. Drive slowly. Practice maneuvering and using the throttle and  
brakes on level surfaces.  
33  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Turning the Vehicle  
1. Before turning, activate  
a turn signal to alert oth-  
ers of your intentions.  
Activate the left signal  
before a left turn. Acti-  
vate the right signal  
before a right turn.  
2. Steer in the direction of  
the turn, leaning your  
upper body to the inside  
of the turn while sup-  
porting your weight on  
the outer footrest. Use  
the same leaning tech-  
nique for turning in  
reverse.  
3. Practice turning at slow speeds before attempting to turn at faster  
speeds.  
34  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Driving on Slippery Surfaces  
Turn in  
direction of  
skid  
Sideways  
skid  
Whenever riding on slippery surfaces such as wet trails or loose gravel,  
or during freezing weather, follow these precautions:  
1. Do not operate on excessively rough, slippery or loose terrain.  
2. Slow down when entering slippery areas.  
3. Engage AWD before wheels begin to lose traction.  
NOTICE: Severe damage to drive train may occur if AWD is engaged while the  
wheels are spinning. Allow the rear wheels to stop spinning before  
engaging AWD, or engage AWD before wheels begin to lose traction.  
4. Be alert.  
5. Watch the trail.  
6. Avoid quick, sharp turns.  
Tip: To correct a rear wheel skid, turn the handlebars in the same direction as  
the skid and shift body weight forward.  
35  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Driving Uphill  
Whenever traveling  
uphill, follow these pre-  
cautions:  
1. Avoid steep hills (25°  
maximum).  
2. Check the terrain  
carefully.  
3. Avoid hills with  
excessively slippery  
or loose surfaces.  
4. Shift your weight  
uphill.  
5. Drive straight uphill.  
25° Maximum  
6. Keep your feet on the  
footrests.  
7. Drive at a steady rate of speed to avoid stalling.  
8. Be alert. Be prepared to take emergency action. This may include  
dismounting quickly.  
9. Never open the throttle suddenly or make sudden gear changes.  
10. Never go over the top of a hill at high speed.  
If all forward speed is lost:  
Keep your weight uphill.  
If the vehicle begins rolling downhill, never apply engine power. Never  
apply the brakes aggressively while rolling backwards.  
Apply the brakes gradually. When fully stopped, lock the parking brake.  
See page 25.  
Dismount on the uphill side, or to either side if the vehicle is pointed  
straight uphill. Turn the vehicle around using the K-Turn. See page 39.  
36  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Driving on a Sidehill (Sidehilling)  
Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is  
necessary, follow these precautions:  
1. Slow down.  
2. Avoid hills with excessively slippery or loose surfaces.  
3. Avoid crossing the sides of steep hills.  
4. Shift your weight uphill.  
5. Keep your feet on the footrests.  
6. If the vehicle begins to tip, quickly turn the front wheels downhill  
(if possible) or dismount on the uphill side immediately!  
37  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Driving Downhill  
25° Maximum  
When driving downhill, follow these precautions:  
1. Check the terrain carefully.  
2. Avoid hills with excessively slippery or loose surfaces.  
3. Never drive downhill at high speed.  
4. Slow down.  
5. Avoid driving downhill at an angle, which can cause the vehicle to  
pitch sharply to one side. Drive straight downhill.  
6. Shift your weight rearward.  
7. Apply the brakes slightly to aid in slowing.  
38  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Turning Around on a Hill (K-Turn)  
If the vehicle stalls while climbing a hill, never back it down the hill!  
Use the K-turn to turn around.  
8 ft. (2.4 m)  
1. Stop the vehicle. Keep your weight uphill.  
2. Lock the parking brake. Leave the transmission in forward gear.  
Turn the engine off.  
3. Dismount on the uphill side of the vehicle, or on the left if the vehi-  
cle is pointing straight uphill.  
4. Staying uphill of the vehicle, turn the handlebars full left. Squeeze  
the brake lever to release the parking brake.  
5. Slowly release the brake lever and allow the vehicle to roll around  
to your right until it's pointing across the hill or slightly downward.  
6. Lock the parking brake. Remount from the uphill side. Keep your  
weight uphill.  
7. Apply the foot brake. Squeeze and release the brake lever to release  
the parking brake.  
8. Release the foot brake and drive slowly downhill. Control speed  
with either the hand or foot brake until the vehicle is on level  
ground.  
39  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Driving Through Water  
Your Polaris vehicle can  
operate through water with  
a maximum recommended  
depth equal to the bottom  
of the footrests. Follow  
these procedures when  
operating through water:  
1. Determine water  
depths and current  
before entering water.  
2. Choose a crossing  
where both banks have  
gradual inclines.  
3. Avoid operating  
through deep or fast-  
flowing water.  
Maximum Depth  
NOTICE: Major engine damage can result if the vehicle is not thoroughly  
inspected after operation in water. Perform the services outlined in  
the maintenance chart. See page 47. The following areas need  
special attention: engine oil, transmission oil, front and rear  
gearcases (if equipped) and all grease fittings.  
If the vehicle tips or overturns in water, or if the engine stops during or  
after operating in water, restarting can result in serious engine  
damage. Transport the vehicle to your dealer for service before  
restarting the engine. If this is not possible, follow the vehicle  
immersion inspection and drying procedures outlined on page 81,  
then see your dealer for service at the first opportunity.  
4. After leaving water, test the brakes. Apply them lightly several  
times while driving slowly. The friction will help dry out the pads.  
If its unavoidable to enter water deeper than the footrest level:  
• Proceed slowly. Avoid rocks and obstacles.  
• Balance your weight carefully. Avoid sudden movements.  
• Maintain a steady rate of speed. Do not make sudden turns or stops.  
Do not make sudden throttle changes.  
40  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Driving Over Obstacles  
Follow these precautions when operating over obstacles:  
1. Always check for obstacles before operating in a new area.  
2. Look ahead and learn to read the terrain. Be constantly alert for haz-  
ards such as logs, rocks and low hanging branches.  
3. Travel slowly and use extra caution when operating on unfamiliar  
terrain. Not all obstacles are immediately visible.  
4. Never attempt to operate over large obstacles, such as rocks or  
fallen trees.  
41  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Driving in Reverse  
Follow these precautions when operating in reverse:  
1. Always check for obstacles or people behind the vehicle.  
2. Always avoid backing downhill.  
3. Back slowly.  
4. Apply the brakes lightly for stopping.  
5. Avoid turning at sharp angles.  
6. Never open the throttle suddenly.  
7. Do not use the override switch unless additional wheel speed is  
required for vehicle movement. Use the override with caution as  
rearward vehicle speed is greatly increased. Do not operate at wide  
open throttle. Operate the throttle just enough to maintain a desired  
speed.  
NOTICE: Excessive throttle operation while in the speed limit mode may cause  
fuel to build in the exhaust, resulting in engine popping and/or engine  
damage.  
42  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Parking on an Incline  
25° maximum  
Avoid parking on an incline if possible. If it's unavoidable, follow these  
precautions:  
1. Stop the engine.  
2. Place the transmission in gear.  
3. Lock the parking brake.  
4. Always block the rear wheels on the downhill side.  
5. Turn the fuel valve off.  
43  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Hauling Cargo  
Overloading the vehicle or carrying or towing cargo improperly can alter vehicle  
handling and may cause loss of control or brake instability, which can result in  
serious injury or death. Always follow these precautions when hauling cargo:  
REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING  
WHEN HAULING CARGO.  
NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle. When  
determining the weight you are adding to the vehicle, include the weight of the  
operator, accessories, loads in the rack or box and the load on the trailer tongue.  
The combined weight of these items must not exceed the maximum weight  
capacity.  
When operating over rough or hilly terrain, reduce speed and cargo to maintain  
stable driving conditions.  
CARRY LOADS AS LOW ON THE RACK AS POSSIBLE. Carrying a load high  
on the rack raises the center of gravity of the vehicle and creates a less stable  
operating condition.  
SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create  
unstable operating conditions, which could result in loss of control of the vehicle.  
OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When  
handling off-centered loads that cannot be centered, securely fasten the load  
and operate with extra caution. Always attach the tow load to the hitch point  
designated for your vehicle.  
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.  
USE EXTREME CAUTION when operating with loads that extend over the rack  
sides. Stability and maneuverability may be adversely affected, causing the  
vehicle to overturn.  
NEVER CARRY CARGO ON THE FRONT OF THE VEHICLE.  
DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle  
should never exceed 10 mph (16 kph) while towing a load on a level 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.  
44  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Hauling Cargo  
Load Distribution  
Accessory racks and hitches are available from your Polaris dealer.  
Read and understand the load distribution warnings listed on the vehicle  
warning labels. Never exceed the specified weights.  
Never carry cargo on the front of the vehicle.  
Cargo should be evenly distributed and mounted as low as possible on  
the rear rack. When operating over rough or hilly terrain, reduce speed  
and cargo or towed load to maintain stable driving conditions.  
Towing Loads  
Towing is approved OFF-ROAD ONLY. Do not exceed the maximum  
capacities when towing. Do not tow any trailer on a grade steeper than  
15°.  
Always attach a towed load to the hitch point. Remove the hitch when  
not towing a trailer. If towing a load, reduce rear rack cargo weight by  
the amount of tongue weight.  
• The combination of rear rack cargo weight and tongue weight must  
not exceed the rear rack capacity.  
• The total load (operator, accessories, cargo and weight on hitch) must  
not exceed the maximum weight capacity of the vehicle.  
45  
Download from Www.Somanuals.com. All Manuals Search And Download.  
EMISSION CONTROL SYSTEMS  
Noise Emission Control System  
Do not modify the engine, intake or exhaust components, as doing so  
may affect compliance with governmental noise level requirements.  
Spark Arrestor  
Your Polaris vehicle has a spark arrestor that was designed for on-road  
and off-road operation. It is required that this spark arrestor remain  
installed and functional when the vehicle is operated.  
Exhaust Emission Control System  
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.  
Electromagnetic Interference  
This spark ignition system complies with Canadian ICES-002.  
This vehicle complies with the EMC requirements of European direc-  
tives 97/24/EC and 2004/108/EC.  
46  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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 111.  
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 (16 km/h). Vehicles subjected to severe use must be  
inspected and serviced more frequently.  
Severe Use Definition  
• Frequent immersion in mud, water or sand  
• Racing or race-style high RPM use  
• Prolonged low speed, heavy load operation  
• Extended idle  
• Short trip cold weather operation  
Pay special attention to the oil level. A rise in oil level during cold  
weather can indicate contaminants collecting in the oil sump or crank-  
case. 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.  
47  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Periodic Maintenance Chart  
Improperly performing the procedures marked with a could result in  
component failure and cause an accident, which may result in serious injury or  
death. Always have an authorized Polaris dealer perform these services.  
Maintenance Chart Key  
X
Perform these operations more often for vehicles subjected to  
severe use.  
E
Emission-related service (Failure to conduct this maintenance will  
not void the emissions warranty but may affect emissions.)  
Q
Have an authorized Polaris dealer perform these services.  
Perform all services at whichever maintenance interval is reached first.  
Item  
Maintenance Interval  
Remarks  
(whichever comes first)  
Hours Calendar  
Miles  
(Km)  
Q
Steering  
-
-
-
-
-
-
-
-
-
-
-
Pre-Ride  
Pre-Ride  
Pre-Ride  
Pre-Ride  
Pre-Ride  
Pre-Ride  
Pre-Ride  
Pre-Ride  
Pre-Ride  
Pre-Ride  
Daily  
-
-
-
-
-
-
-
-
-
-
-
Make adjustments as need  
ed. See Pre-Ride Checklist  
on page 30.  
X Front suspension  
X Rear suspension  
Tires  
X Brake fluid level  
X Brake lever travel  
Brake system  
Wheels/fasteners  
Frame fasteners  
X Engine oil level  
X Air filter, pre-filter  
E
Inspect; clean often; replace  
as needed  
X Air box sediment  
-
Daily  
Daily  
-
-
-
Drain deposits when visible  
tube  
Headlamp/tail  
lamp  
-
-
Check operation; apply  
dielectric grease if replacing  
X Air filter,  
E main element  
Weekly  
Monthly  
Inspect; replace as needed  
X Brake pad wear  
10 H  
100 (160) Inspect periodically  
Q
48  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Periodic Maintenance Chart  
Item  
Maintenance Interval  
Remarks  
(whichever comes first)  
Hours Calendar  
Miles  
(Km)  
Battery  
20 H  
Monthly  
Monthly  
Monthly  
Monthly  
200 (320) Check terminals; clean; test  
250 (400) Inspect level; change yearly  
250 (400) Inspect level; change yearly  
250 (400) Inspect; clean if needed  
X Demand drive fluid 25 H  
X Transmission oil  
25 H  
25 H  
X Engine breather  
E filter (if equipped)  
X General  
50 H  
50 H  
50 H  
50 H  
50 H  
50 H  
50 H  
3 M  
6 M  
6 M  
6 M  
6 M  
6 M  
6 M  
500 (800) Lubricate all fittings, pivots,  
cables, etc.  
lubrication  
Carburetor float  
bowl  
500 (800) Drain bowl periodically and  
prior to storage  
Q
E
Throttle Cable/  
ETC Switch  
Choke cable  
500 (800) Inspect; adjust; lubricate;  
replace if necessary  
Q
E
500 (800) Inspect; adjust; lubricate;  
replace if necessary  
E Carburetor air  
500 (800 Inspect duct for proper seal-  
ing/air leaks  
intake ducts/flange  
Drive belt  
500 (800) Inspect; adjust; replace as  
needed  
Cooling system  
(if applicable)  
1000 (1600) Inspect coolant strength  
seasonally; pressure test  
system yearly  
X Engine oil change 100 H  
X Oil filter change 100 H  
6 M  
1000 (1600) Perform a break-in oil change  
at 20 hours  
6 M  
1000 (1600) Replace with oil change  
1000 (1600) Inspect routing, condition  
X Oil tank vent hose 100 H  
12 M  
(if equipped)  
Q
E
Q
E
Valve clearance  
100 H  
100 H  
12 M  
12 M  
1000 (1600) Inspect; adjust  
Fuel system/filter  
1000 (1600) Check for leaks at tank cap,  
lines, fuel valve, filter, pump,  
carburetor; replace lines  
every two years  
X Perform these procedures more often for vehicles subjected to severe use.  
E Emission-Related Service  
Q Have an authorized Polaris dealer perform these services.  
49  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Periodic Maintenance Chart  
Item  
Maintenance Interval  
Remarks  
(whichever comes first)  
Hours Calendar  
Miles  
(Km)  
X Radiator  
100 H  
100 H  
12 M  
12 M  
1000 (1600) Inspect; clean external  
surfaces  
(if applicable)  
X Cooling hoses  
1000 (1600) Inspect for leaks  
(if applicable)  
X Engine mounts  
100 H  
100 H  
12 M  
12 M  
1000 (1600) Inspect  
1000 (1600) Inspect  
Exhaust muffler/  
pipe  
Q
E
Q
E
Spark plug  
100 H  
100 H  
100 H  
12 M  
12 M  
12 M  
1000 (1600) Inspect; replace as needed  
1000 (1600) Inspect  
Ignition Timing  
X Wiring  
1000 (1600) Inspect for wear, routing,  
security; apply dielectric  
grease to connectors  
subjected to water, mud, etc.  
Q
Clutches (drive  
100 H  
100 H  
12 M  
12 M  
1000 (1600) Inspect; clean; replace worn  
parts  
and driven)  
Q
Front wheel  
bearings  
1000 (1600) Inspect; replace as needed  
Q
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  
Q
Toe adjustment  
-
Inspect periodically; adjust  
when parts are replaced  
Headlight aim  
-
Adjust as needed  
50  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Lubrication Guide  
Check and lubricate all components at the intervals outlined in the Peri-  
odic Maintenance Chart beginning on page 47. Items not listed in the  
chart should be lubricated at the General Lubrication interval.  
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.  
Item  
Lube  
Method  
Engine Oil  
PS-4 PLUS Performance See page 52.  
Synthetic 2W-50  
Brake Fluid  
DOT 4 Only  
See page 59.  
Drive Chain(s)  
O-ring chain lube or SAE Lubricate.  
80/90  
Transmission Oil  
AGL Synthetic Gearcase See page 56.  
Lube  
Demand Drive Fluid Demand Drive LT  
See page 58.  
(Front Gearcase)  
Premium Fluid  
Front Prop Shaft  
Yoke  
Premium U-Joint Lube  
Grease fittings (3 pumps maximum)  
every 500 miles (800 km), before long  
periods of storage, or after pressure  
washing or submerging.  
Front Prop Shaft Yoke  
51  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Engine Oil  
Oil Recommendations  
Always change the oil filter whenever changing oil.  
Polaris recommends the use of Polaris PS-4 PLUS Performance Syn-  
thetic 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 tempera-  
ture operation. See page 99 for the part numbers of Polaris products.  
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 Specifications  
Lubricant  
Capacity  
Drain Plug Torque  
PS-4 PLUS Performance  
Synthetic 2W-50 4-Cycle Oil  
2 qts. (1.9 l)  
14-17 ft. lbs. (19-23 Nm)  
Oil Level  
The oil dipstick is located on the left  
side of the vehicle.  
1. Position the vehicle on a level  
surface. Place the transmission in  
neutral. Lock the parking brake.  
2. Start the engine. Allow it to idle  
for 30 seconds. Stop the engine.  
3. Remove the dipstick. Wipe it dry  
with a clean cloth.  
Safe Range  
4. Reinstall the dipstick completely.  
Make sure the cap is fully seated  
to keep the angle and depth of the  
stick consistent.  
5. Remove the dipstick and check  
the oil level. Add oil as needed.  
Maintain the oil level in the safe  
range. Do not overfill.  
Safe  
Add Oil  
6. Reinstall the dipstick.  
52  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Oil and Filter Change  
Always change the oil and filter at the intervals outlined in the Periodic  
Maintenance Chart beginning on page 47. Always change the oil filter  
whenever changing oil.  
1. Position the vehicle on a level surface. Clean the area around the  
drain plug at the bottom of the oil tank and the bottom of the engine.  
2. Start the engine. Allow it to idle for two to three minutes. Stop the  
engine.  
3. Place a drain pan under the oil tank. Remove the drain plug. Allow  
the oil to drain completely.  
Hot oil can cause burns to skin. Do not allow hot oil to contact skin.  
4. Reinstall the drain plug with  
a new sealing washer.  
Torque to specification. See  
Sealing  
Washer  
Screen  
Fitting  
page 52.  
Tip: The sealing surfaces on the  
drain plug and crankcase  
should be clean and free of  
burrs, nicks or scratches.  
Drain  
Plug  
5. Disconnect the lower oil  
delivery hose and remove  
the screen fitting from the  
oil tank. Clean the fitting.  
NOTICE: The fitting threads must  
be sealed with LOCTITE  
PST 505 or PTFE seal  
tape.  
6. Reinstall the screen fitting  
and rotate the fitting clock-  
wise a minimum of 2 1/2  
Mark  
turns into the tank threads. Continue to rotate the fitting until the  
nipple of the fitting aligns with the mark on the tank.  
NOTICE: Do not over-tighten. Maximum torque for the screen fitting is 25 ft.  
lbs. (34 Nm).  
7. Reattach the oil line.  
53  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Oil and Filter Change  
8. Place towels under the oil filter.  
Using an oil filter wrench, turn  
the filter counterclockwise to  
remove it.  
9. Lubricate the gasket on the new  
filter with a film of new engine  
oil. Check to make sure the  
gasket is in good condition.  
Make sure the gasket from the  
old filter is not still on the  
engine.  
10. Install the new oil filter. After  
the filter contacts the engine  
surface, turn it 1/2 to 3/4 turn  
by hand.  
Filter  
11. Approximately one cup of engine oil will remain in the crankcase.  
To drain, remove the drain plug on the lower right side of the crank-  
case.  
Tip: The sealing surfaces on the drain plug and crankcase should be clean and  
free of burrs, nicks or scratches.  
12. Reinstall the drain plug and torque to 14 ft. lbs. (19 Nm).  
13. Remove the dipstick. Add the recommended oil. See page 52. Rein-  
stall the dipstick.  
Tip: If the sump is not drained, add about 1 3/4 quarts initially.  
14. Place the transmission in neutral. Lock the parking brake.  
15. Prime the oil pump using the procedure on page 55. Then stop the  
engine and inspect for leaks.  
16. Remove the dipstick and check the oil level. Add oil as needed.  
Maintain the oil level in the safe range. Do not overfill.  
17. Discard used oil and filter properly.  
54  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Oil and Filter Change  
Oil Pump Priming  
This priming procedure must  
be performed whenever the oil  
hose connection between the  
oil tank and pump inlet has  
been disconnected.  
2” (5 cm)  
Relief  
Slit  
1. Clamp or pinch off the vent  
line approximately two  
inches (5 cm) from the oil  
tank, between the end of  
the oil tank vent fitting and  
the vent line's pressure  
relief slit.  
Oil  
Tank  
Vent  
Line  
2. Run the engine for 10-20  
seconds.  
3. Remove the vent line  
clamp. If the line is bled  
properly, you should hear a  
rush of air, indicating that  
the line is properly primed  
and ready for operation. If  
you do not hear air, the  
line has not bled, and  
you'll need to repeat the  
priming procedure.  
55  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Transmission Oil  
Always check and change the transmission oil at the intervals outlined  
in the Periodic Maintenance Chart beginning on page 47. Maintain the  
oil level at the bottom of the fill hole threads. See page 99 for the part  
numbers of Polaris products.  
The fill plug is located on the left side of the vehicle, under the rear  
fender, behind the wheel. The drain plug is located behind the wheel  
well.  
Transmission Oil Recommendations  
Gearcase  
Lubricant  
Capacity  
Fill Plug  
Torque  
Drain Plug  
Torque  
Transmission Premium AGL Synthetic  
Gearcase Lubricant  
32 oz.  
(946 ml)  
14 ft. lbs.  
(19 Nm)  
14 ft. lbs.  
(19 Nm)  
Oil Check  
1. Position the vehicle on a level sur-  
face.  
2. Remove the propshaft shield from  
the right side of the vehicle to  
access the fill plug. Remove the  
fill plug.  
3. Check the oil level. Add oil as  
needed. Do not overfill.  
4. Reinstall the fill plug. Torque to  
specification.  
Fill Plug  
56  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Transmission Oil  
Oil Change  
1. Position the vehicle on a level surface.  
2. Remove the propshaft shield from the right side of the vehicle to  
access the fill plug. Remove the fill plug.  
3. Remove the transmission drain plug located on the bottom left-hand  
side and drain the oil into an appropriate container. Discard used oil  
properly.  
4. Clean and reinstall the drain plug. Torque to specification.  
5. Add the proper amount of the recommended lubricant.  
6. Reinstall the fill plug. Torque to specification.  
7. Check for leaks.  
8. Reinstall the propshaft shield.  
57  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Front Gearcase (Demand Drive) Fluid  
Always check and change the demand drive fluid at the intervals out-  
lined in the Periodic Maintenance Chart beginning on page 47. Maintain  
the fluid level at the bottom of the fill hole threads. See page 99 for the  
part numbers of Polaris products.  
Fluid Recommendations  
Gearcase  
Lubricant  
Capacity  
Fill Plug  
Torque  
Drain Plug  
Torque  
Front  
Gearcase  
Demand Drive LT  
Premium Fluid  
9 oz.  
(265 ml)  
8-10 ft. lbs.  
(11-14 Nm)  
11 ft. lbs.  
(15 Nm)  
Fluid Check  
The fill plug is located on the right side of the demand drive unit.  
1. Position the vehicle on a  
level surface.  
Fill  
Plug  
2. Remove the fill plug.  
Check the fluid level.  
3. Add the recommended  
demand drive fluid as  
needed to bring the level  
to the bottom of the fill  
hole threads.  
Fill Level  
Drain Plug  
4. Reinstall the fill plug.  
Torque to specification.  
Fluid Change  
The drain plug is located on the bottom right side of the unit.  
1. Position the vehicle on a level surface.  
2. Remove the fill plug.  
3. Place a drain pan under the demand drive unit. Remove the drain  
plug. Allow the fluid to drain completely.  
4. Clean and reinstall the drain plug. Torque to specification.  
5. Add the recommended fluid to capacity.  
6. Reinstall the fill plug. Torque to specification.  
7. Check for leaks.  
8. Dispose of used fluid properly.  
58  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Brake Fluid  
Check brake fluid levels for both brake systems before each ride.  
Always maintain brake fluid at the recommended level. Do not overfill.  
The brakes should feel firm when they're applied. Spongy or weak  
brakes may indicate a fluid leak or low fluid level. A low fluid level  
may also mean that brake pads are worn and need to be replaced. Do not  
operate the vehicle with spongy or weak brakes. See your dealer for ser-  
vice.  
Operating the vehicle with a spongy brake can result in loss of braking, which  
could cause an accident. Never operate the vehicle with spongy-feeling brakes.  
If the fluid level is low add DOT 4 brake fluid only. See page 99 for the  
part numbers of Polaris products.  
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.  
Under normal operation, the diaphragm extends into the reservoir as  
fluid level drops. If the fluid level is low and the diaphragm is not  
extended, a leak is likely and the diaphragm should be replaced. To  
ensure proper diaphragm operation, always fill the reservoir as needed  
whenever the cover is loosened or removed. Do not overfill.  
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.  
59  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Brake Fluid  
Hand Brake  
The master cylinder is  
located on the left  
Indicator  
Window  
Master  
Cylinder  
handlebar. Maintain the  
fluid level 6 mm below  
the top edge of the master  
cylinder. Do not overfill.  
1. Position the vehicle on a level surface. Make sure the handlebars are  
straight.  
2. View the fluid level through the indicator window (eye) on the top  
of the master cylinder. The eye will appear dark when the fluid level  
is full. When fluid is low, the eye will be clear.  
3. Add the recommended fluid as needed. Do not overfill.  
Foot Brake  
1. Position the vehicle on a level surface.  
2. The brake fluid reservoir is located either under the seat or near the  
foot brake. View the fluid level in the master cylinder.  
3. Maintain the fluid level between the minimum and maximum  
marks. Do not overfill.  
60  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Brakes  
The front and rear brakes are hydraulic disc brakes. Both brake systems  
are self-adjusting.  
Brake Inspections  
Perform the following checks to keep the brake systems in good operat-  
ing condition. Check more often if brakes are used heavily under normal  
operation.  
1. Always keep brake fluid at an  
adequate level. See page 59.  
2. Check the brake systems regularly  
for fluid leaks.  
3. Check the brakes for excessive  
travel or spongy feel.  
4. Check the friction pads for wear,  
damage and looseness. Replace  
the pads when the friction mate-  
rial is worn to 1 mm.  
5. Check the security and surface  
condition of the disc.  
1 mm  
Side Panel Removal  
Tip: Side panel removal may be difficult until the locking tabs and receivers have  
been snapped and unsnapped a few times.  
1. Remove the seat.  
2. Remove the push-pins at the front and rear of the side panel.  
3. Grasp the rear of the side panel near the rear cab. Pull the panel  
slightly outward, downward and rearward to disengage the upper  
front section.  
4. To reinstall the side panel, align the upper and lower front section  
with the mating front cab tabs. Push the panel upward and forward  
until the panel is fully seated at the front. Lock the rear of the panel  
into the rear front cab tabs. Reinstall the push-pins at the front and  
rear of the side panel.  
61  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Toe Alignment  
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 3-6 mm 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.  
2
4. Measure the distance  
between the marks and  
1
record the measurement (1).  
5. Move the vehicle until the  
chalk marks are at the rear  
of the tires, even with the  
hub/axle center line.  
6. Measure the distance between the marks and record the  
measurement (2).  
7. Subtract measurement 2 from measurement 1. The difference is the  
vehicle toe-out alignment.  
8. If you discover improper alignment, see your Polaris dealer for ser-  
vice.  
62  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Steering Assembly  
Check the steering assembly of the vehicle periodically for loose nuts  
and bolts. If loose nuts and bolts are found, see your Polaris dealer for  
service before operating the vehicle.  
Rear Suspension  
The rear suspension spring pre-  
load and shock compression  
damping may be adjusted to suit  
different riding conditions and  
operator weight.  
Locking  
Ring  
2
Spring Preload  
1
1. Raise and safely support the  
rear of the vehicle off the  
ground to allow the suspen-  
sion to fully extend.  
2. Loosen the jam nut and  
back it away from the  
adjusting ring.  
Adjusting  
Ring  
3. As viewed from the top of  
the shock, turn the adjusting  
ring clockwise (1) to  
increase preload. Turn the  
ring counter-clockwise (2)  
to decrease preload.  
4. Tighten the jam nut firmly  
against the adjuster ring.  
63  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Throttle Cable Freeplay  
Adjust throttle cable freeplay at the  
handlebar.  
1. Slide the boots off the inline cable  
adjuster sleeve. Loosen the  
adjuster locknut.  
2. Turn the adjuster until 1.5-3 mm of  
freeplay is achieved at the thumb  
lever. Move the throttle lever back  
and forth several times while  
adjusting.  
3. Tighten the lock nut and slide the  
boots over the cable adjuster until  
they touch at the midpoint of the  
adjuster.  
1.6-3 mm  
Tip: Engine RPM should not increase when steering is turned full left or right.  
Readjust cable freeplay if this occurs.  
Boot  
Boot  
Sleeve  
Lock Nut  
64  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Tires  
WARNING  
Operating your vehicle with worn tires, improperly inflated tires, non-standard  
tires or improperly installed tires will affect vehicle handling and could cause an  
accident.  
• Maintain proper tire pressure as described on the label on your vehicle and in  
the specifications section of the owner's manual.  
• Use only original equipment size and type when replacing tires.  
• Make sure the wheels are installed properly.  
• Replace tires when the tread depth measures 3 mm or less.  
Refer to the specifications section beginning on page 104 for recom-  
mended tire type, size and pressure.  
Front Wheel Hub Tightening  
Front wheel bearing tightness and spindle nut retention are critical com-  
ponent operations. All service must be performed by your authorized  
Polaris dealer.  
Tire Tread Depth  
Always replace tires  
when tread depth is  
worn to 3 mm or less.  
3 mm  
65  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Tires  
Wheel Removal  
1. Position the vehicle on a level surface. Place the transmission in  
gear. Lock the parking brake.  
2. Loosen the wheel nuts slightly.  
Do not service axle nuts that have a cotter pin installed. See your Polaris dealer.  
3. Place a suitable stand under the  
footrest frame to raise the wheel  
slightly off the ground.  
4. Remove the wheel nuts.  
5. Remove the wheel.  
Wheel Installation  
1. Place the wheel on the wheel hub  
with the valve stem toward the  
outside and the rotation arrows on  
the tire pointing toward forward  
rotation.  
2. Install the wheel nuts finger tight.  
On vehicles with tapered rear  
wheel nuts, make sure the tapered  
ends of the nuts fit into the tapers  
on the wheels.  
3. Lower the vehicle to the ground.  
4. Torque the wheel nuts to  
specification (page 67).  
Loose nuts could cause a tire to come off during operation, which could result in  
an accident or overturn. Always ensure that all nuts are torqued to specification.  
66  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Tires  
Wheel Nut Torque Specifications  
27 ft. lbs. (37 Nm)  
50 ft. lbs. (68 Nm)  
Check the wheel nut torques occasionally and when they've been loos-  
ened for service.  
Item  
Torque Specification  
Front Wheel Nuts  
Rear Wheel Nuts  
27 ft. lbs. (37 Nm)  
50 ft. lbs. (68 Nm)  
67  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Air Filter  
1. Remove the seat.  
Pre-Filter  
Main Filter  
2. Release the air box cover  
clips, and remove the air  
box cover.  
3. Loosen the clamp and  
remove the filter.  
4. Remove the fabric type pre-  
filter from the main filter.  
Wash the pre-filter in soapy  
water, then rinse and let dry.  
5. Reinstall the pre-filter over  
the main filter. Install a new  
main filter if needed.  
6. Reinstall the filter into the  
air box and tighten the  
clamp. Do not over-tighten  
the clamp, as filter damage  
could occur.  
Breather  
Filter  
7. Reinstall the air box cover and the seat.  
Breather Filter  
The breather filter is on the hose that runs between the engine and air  
box.  
1. Remove the clamps and pull the breather filter out of the hoses. It's  
not necessary to remove the lower hose from the engine.  
2. Inspect the filter for debris. Blow gently through the filter in the  
direction of the arrow to check for clogging. Replace if needed.  
3. Check the hoses for cracks, deterioration, abrasion, or leaks.  
Replace as needed.  
4. Reinstall the filter and secure the clamps. The filter is effective with  
the arrow pointing in either direction.  
Operation of your vehicle without a breather filter can cause engine damage.  
Always reinstall the breather filter after removing it for service.  
68  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Handlebars  
The handlebars can be adjusted for rider preference.  
Improper adjustment of the handlebars or incorrect torquing of the adjuster  
block tightening bolts can cause limited steering or loosening of the handlebars,  
resulting in loss of control. Follow the adjustment procedures exactly, or see  
your Polaris dealer for service.  
1. Remove the handlebar cover to  
access the handlebar bolts.  
Handlebar Bolts  
2. Loosen the four handlebar bolts.  
3. Adjust the handlebar to the  
desired height.  
4. 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.  
5. Torque the front two bolts to 14-17 Nm, then torque the rear two  
bolts. A gap of up to 3 mm will remain at the rear bolts.  
69  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Carburetor  
Your Polaris vehicle is calibrated at the factory for optimal performance  
at altitudes ranging from zero to 1800 meters and at temperatures of 4  
degrees C. or higher. Above 1800 meters the engine air/fuel mixture  
becomes too rich and the engine loses approximately 3% of its power  
for each 300 meter 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 and clutch components,  
available from your Polaris dealer, are required for operation above  
1800 meters and at temperatures below 4 degrees C.  
Tip: Continuous operation of the engine without proper jetting when required  
can cause poor performance, overheating or PVT or engine damage. See  
your Polaris dealer for more information about jetting the vehicle for condi-  
tions in your area.  
Carburetor/Engine Idle RPM Adjustment  
If the engine idle speed is not satisfac-  
tory, and all other conditions are favor-  
able, the carburetor can be adjusted.  
1. Place the transmission in gear. Lock  
the parking brake.  
2. Start the engine and allow it to warm  
up for approximately five minutes.  
3. Turn the screw in (clockwise) to  
raise RPM. Turn the screw out  
(counterclockwise) to lower RPM.  
Idle  
Adjuster  
70  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Drive Chain  
Drive Chain Lubrication  
The drive chains are equipped with o-ring-sealed, permanently greased  
pins and rollers. However, the outer surfaces of the roller must be lubri-  
cated.  
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 mm).  
Regularly lubricate the drive chain with Polaris Chain Lube, an SAE 80-  
90 lube or an approved o-ring chain spray lube. See page 99 for the part  
numbers of Polaris products.  
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.  
71  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Drive Chain  
Rear Drive Chain Slack  
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" (5 mm - 10 mm) deflection.  
Adjusting or operating the vehicle 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.  
1
3/16"-3/8" (5 mm - 10 mm)  
Use the following procedure if adjustment is required.  
1. Remove the chain guard.  
Pin Punch  
2. Loosen the chain guide.  
3. Loosen the two eccentric  
locking bolts.  
4. Loosen the caliper mounting  
bolt located on the left side  
of the swing arm.  
Locking Bolts  
5. Insert a pin punch through  
the sprocket hub and into the  
eccentric housing.  
72  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Drive Chain  
Rear Drive Chain Slack  
6. Roll the vehicle forward or back-  
ward to adjust the chain slack to the  
proper tension. See the illustration  
for proper splice link clip opening  
position.  
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.  
Clip  
Position  
8. Tighten the caliper mount bolt to 15  
ft. lbs. (20 Nm).  
9. Remove the pin punch.  
10. Roll the vehicle forward, checking chain tension in several places  
around the chain.  
Tip: 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" (3 mm) clearance and tighten  
the retaining bolt to 5 ft. lbs. (7 Nm).  
12. Reinstall the chain guard.  
73  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Cooling System  
The engine coolant level is controlled, or maintained, by the recovery  
system. The recovery system components are the recovery bottle, the  
radiator filler neck, the radiator pressure cap and the connecting hose.  
As coolant operating temperature increases, the expanding (heated)  
excess coolant is forced out of the radiator, past the pressure cap, and  
into the recovery bottle. As engine coolant temperature decreases, the  
contracting (cooled) coolant is drawn back up from the bottle, past the  
pressure cap, and into the radiator.  
Some coolant level drop on new vehicles is normal as the system is  
purging itself of trapped air. Check the coolant level and maintain as  
recommended by adding coolant to the recovery bottle.  
Polaris recommends the use of Polaris Premium 60/40 anti-freeze/cool-  
ant or a 50/50 mixture of high quality aluminum compatible anti-freeze/  
coolant and distilled water. Polaris Premium 60/40 is already premixed  
and ready to use. Do not dilute with water. See page 99 for the part num-  
bers of Polaris products.  
Always follow the manufacturer's mixing recommendations for the  
freeze protection required in your area.  
Recovery Bottle Coolant  
The recovery bottle is located on  
the left side of the vehicle.  
1. Maintain the coolant level  
between the minimum and  
maximum marks on the bottle  
(when the fluid is cool).  
2. Add coolant as needed.  
Recovery Bottle  
74  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Cooling System  
Radiator Coolant  
To ensure that the coolant maintains its ability to protect the engine,  
Polaris recommends that you drain the system completely every two  
years and add a fresh mixture of antifreeze and water.  
Replace the coolant any time the cooling system has been drained for  
maintenance or repair. If the recovery bottle has run dry, check the level  
in the radiator. Add coolant as needed.  
Escaping steam can cause burns. Never remove the pressure cap while the  
engine is warm or hot. Always allow the engine to cool before removing the  
pressure cap.  
1. Remove the front panel to access  
Radiator Cap  
the radiator pressure cap.  
2. Remove the pressure cap.  
3. If coolant is low, use a funnel and  
slowly add coolant through the  
radiator filler neck.  
4. Reinstall the pressure cap. Use of  
a non-standard pressure cap will  
not allow the recovery system to  
function properly. Contact your  
dealer for the correct replacement  
part.  
5. Secure the front panel.  
6. Fill the coolant recovery bottle to  
the upper mark on the bottle.  
7. Check the coolant level in the bottle frequently, adding coolant as  
needed until the level stabilizes.  
75  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Lights  
Headlight Beam Adjustment  
The headlight beam can be adjusted slightly upward or downward. Use  
the following procedure to make the adjustment.  
25 ft.  
(7.6 m)  
X
X
2" (5 cm)  
1. Position the vehicle on a level surface with the headlight approxi-  
mately 25 ft. (7.6 m) from a wall.  
2. Place the transmission in neutral.  
3. Lock the parking brake.  
4. Measure the distance from the floor to the center of the headlight  
and make a mark on the wall at the same height. Include rider  
weight on the seat when measuring.  
5. Start the engine. Switch the headlight to high beam.  
6. Observe the headlight aim on the wall. The most intense part of the  
headlight beam should be two inches (5 cm) below the mark on the  
wall.  
7. Tighten or loosen the lower headlight screws to adjust the beam  
upward or downward or to the left or right.  
76  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Lights  
Poor lighting can result in loss of control or an accident. Lights become dirty  
during normal operation. Wash the headlights and taillights frequently.  
Hot components can cause burns to skin. Allow lamps to cool before servicing.  
Headlamp Replacement  
When servicing a halogen lamp, do  
not touch the lamp with bare fingers.  
Oil from your skin leaves a residue,  
causing a hot spot that will shorten  
the life of the lamp. Hold the plastic  
part of the lamp.  
1. Remove the wire harness connector from the back of the headlight.  
2. Grasp the bulb housing and turn it counterclockwise to remove the  
bulb.  
3. Apply dielectric grease to the light bulb socket before installing the  
new bulb. Install the replacement bulb into the headlight housing  
and rotate clockwise firmly.  
Tip: The bulb must be positioned so the harness installs into the lamp at the bot-  
tom.  
4. Reinstall the connector to the back of the headlight.  
77  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Lights  
Taillight/Brakelight Lamp Replacement  
1. Remove the taillight lens  
Screw  
cover mounting screws.  
Remove the lens cover  
and gasket and set aside  
for reassembly.  
Cover  
Lamp  
2. Remove the lamp.  
3. Apply dielectric grease  
to the socket and install  
the new lamp.  
4. Test the taillight/brake  
light for proper opera-  
tion.  
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 pliers 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.  
78  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Spark Plugs  
Spark Plug Recommendations  
Refer to the specifications section beginning on page 104 for the recom-  
mended spark plug type and gap for your vehicle.  
NOTICE: Using non-recommended spark plugs can result in serious engine  
damage. Always use Polaris-recommended spark plugs.  
Plug Condition  
Torque Specification  
New Spark Plug  
12-15 Nm  
23-27 Nm  
Previously Installed Spark Plug  
Spark Plug Inspection  
Check the spark plug firing end condition after the engine has been  
warmed up and the vehicle has been driven at higher speeds. Immedi-  
ately check the spark plug for correct color. See page 80.  
A hot exhaust system and engine can cause burns. Wear protective gloves  
when removing a spark plug for inspection.  
1. Rotate the spark plug cap.  
2. Using the special wrench provided in the tool pouch, rotate the  
spark plug counterclockwise to remove it.  
3. Inspect the electrodes for wear  
and carbon buildup. Replace  
worn or fouled plugs. Verify that  
the gap is at specification before  
installation.  
4. Reverse the procedure for spark  
plug installation. Torque to  
specification.  
79  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Spark Plugs  
Spark Plug Condition  
Normal Spark Plug  
The normal insulator tip is gray, tan or light brown. There will be few  
combustion deposits. The electrodes are not burned or eroded. This indi-  
cates the proper type and heat range for the engine and the service.  
The tip should not be flaky and white. A white insulator tip indicates  
overheating, caused by use of an improper spark plug or incorrect carbu-  
retion adjustments.  
Wet Fouled Spark Plug  
The wet fouled insulator tip is black. A damp oil film covers the firing  
end. There may be a carbon layer over the entire nose. Generally, the  
electrodes are not worn. General causes of fouling are excessive oil, use  
of non-recommended oil, improper use of the choke, or incorrect throt-  
tle body/carburetor adjustments.  
80  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Vehicle Immersion  
If your vehicle becomes immersed, major engine damage can result if  
the machine is not thoroughly inspected. Take the vehicle to your dealer  
before starting the engine.  
If it's impossible to take your vehicle to a dealer before starting it, fol-  
low the steps outlined below.  
1. Move the vehicle out of the  
water.  
2. Turn the fuel valve off.  
3. Check the air box. If water is  
present, dry the air box and  
replace the filter with a new filter.  
4. Remove the spark plug.  
5. Loosen the carburetor drain screw  
and drain the carburetor.  
6. Turn the engine over several times  
using the electric start.  
7. Dry the spark plug. Reinstall the plug  
or install a new plug.  
8. Tighten the carburetor drain screw.  
9. Turn the fuel valve on.  
10. Attempt to start the engine. If neces-  
Drain Screw  
sary, repeat the drying procedure.  
11. Have the vehicle serviced by your  
dealer promptly, whether you succeed in starting it or not.  
12. If water has been ingested into the transmission, follow the proce-  
dure on page 85 for drying.  
81  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Spark Arrestor  
WARNING  
Failure to heed the following warnings while servicing the spark arrestor could  
result in serious injury or death. Never run the engine in an enclosed area.  
Remove any combustible materials from the area. Wear eye protection and  
leather work gloves. Do not stand behind or in front of the vehicle while purging.  
Never go under the vehicle while it's inclined.  
The exhaust system can get extremely hot. Do not perform service on the spark  
arrestor while the system is hot. Allow components to cool sufficiently before  
proceeding.  
Use the following procedure to periodically purge accumulated carbon  
from the exhaust pipe/muffler.  
1. Position the vehicle on a  
level surface.  
Exhaust  
Outlet  
2. Place the transmission in  
neutral.  
3. Lock the parking brake.  
4. Remove the arrestor clean-  
out plug from the bottom  
of the muffler.  
Clean-Out Plug  
5. Start the engine.  
6. Quickly squeeze and release the throttle lever several times to purge  
carbon from the system.  
7. If carbon comes out of the exhaust, cover or plug the exhaust outlet.  
Wear protective gloves.  
8. Lightly tap on the exhaust pipe with a rubber mallet while repeating  
step 6.  
9. If particles are still suspected to be in the muffler, elevate the rear of  
the vehicle one foot (30 cm) higher than the front. Block the wheels.  
10. Repeat steps 6 to 8 until no more particles are expelled.  
11. Stop the engine. Allow the arrestor to cool.  
12. Reinstall the arrestor plug and remove the exhaust outlet cover or  
plug.  
82  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
83  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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 cen-  
trifugal force decreases, reducing the amount of belt pinch. This begins  
to occur at speeds of less than 5 MPH (8 km/h), due to the system's  
dependence on engine speed.  
For example, when operating at a ground speed of 3 MPH (5 km/h), the  
engine would be running at only about 1500 RPM, with an engagement  
speed of about 1400 RPM. Whenever operating this close to the engage-  
ment speed, the engine may be running at a speed too low to provide the  
pinch needed to prevent belt slip. Belt slip is responsible for creating the  
excessive heat that destroys belts, wears clutch components and causes  
outer clutch covers to fail.  
If the vehicle will be operated for extended periods below 5 MPH (8  
km/h), 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 greatly  
extends the life of the PVT components (belt, cover, etc.).  
Tip: Avoid heavy pulling and extended low-speed operation.  
84  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
PVT System  
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 operat-  
ing.  
1. Move the vehicle out of the water.  
2. Remove the PVT drain plug. Allow the water to drain completely.  
Reinstall the drain plug.  
3. Start the engine. Place the transmission in neutral.  
4. 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.  
5. Allow the engine RPM to settle to idle speed, then shift the trans-  
mission into forward gear.  
6. Test for belt slippage. If the belt slips, repeat the process.  
7. Take the vehicle to your dealer for service as soon as possible.  
85  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Battery  
WARNING  
Improperly connecting or disconnecting battery cables can result in an explosion  
and cause serious injury or death. When removing the battery, always  
disconnect the negative (black) cable first. When reinstalling the battery, always  
connect the negative (black) cable last.  
WARNING  
Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can  
result from contact with skin, eyes or clothing.  
Antidote:  
External: Flush with water.  
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.  
Your vehicle may have either a sealed battery, which requires little  
maintenance, or a conventional battery. A sealed battery can be identi-  
fied 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 termi-  
nals with dielectric grease or petroleum jelly. Be careful not to allow  
cleaning solution or tap water into a conventional battery.  
86  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Battery  
Battery Removal  
1. Place the transmission in gear.  
2. Lock the parking brake.  
3. Remove the seat.  
4. Disconnect the battery hold-down strap.  
5. Remove the battery cover (if equipped).  
6. On conventional batteries, remove the battery vent tube.  
7. Disconnect the black (negative) battery cable first.  
8. Disconnect the red (positive) battery cable last.  
9. Lift the battery out of the vehicle. Be careful not to tip a conven-  
tional battery sideways, which could spill electrolyte.  
NOTICE: 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.  
87  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Battery  
Battery Installation  
Using a new battery that has not been fully charged can damage the bat-  
tery and result in a shorter life. It can also hinder vehicle performance.  
Follow the battery charging instructions on page 90 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 bat-  
teries do not have a vent tube). The vent tube must be free of  
obstructions and securely installed. Route the tube away from the  
frame and vehicle body to prevent contact with electrolyte.  
Battery 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 (if equipped).  
8. Secure the battery hold-down strap.  
9. Verify that cables are properly routed. Cables should be safely  
tucked away at the front and rear of the battery.  
10. Reinstall the seat.  
88  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Battery  
Battery Storage  
Whenever the vehicle is not used for a period of three months or more,  
remove the battery from the vehicle, ensure that it's fully charged, and  
store it out of the sun in a cool, dry place. Check battery voltage each  
month during storage and recharge as needed to maintain a full charge.  
Tip: Power plug leads may need to be bent down so that the battery cover can  
be installed.  
Polaris recommends maintaining battery charge by using a Polaris Bat-  
tery 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 99 for the part numbers of  
Polaris products.  
Battery Fluid (Conventional Battery)  
A poorly maintained battery will  
Upper  
Mark  
Lower  
Mark  
deteriorate rapidly. Check the battery  
fluid level often. Maintain the fluid  
level between the upper and lower  
level marks.  
Add only distilled water. Tap water  
contains minerals that are harmful to  
a battery.  
89  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Battery  
Battery Charging (Conventional Battery)  
1. Remove the battery from the vehicle to prevent damage from leak-  
ing or spilled electrolyte during charging. See page 87.  
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 grav-  
ity to 1.270 or greater.  
3. Reinstall the battery. See page 88. Make sure the positive terminal is  
toward the front of the vehicle.  
Battery Charging (Sealed Battery)  
The following battery charging instructions apply only to the installa-  
tion 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.  
An overheated battery may 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 at 1.2 amps  
or less until battery voltage is 12.8 or greater.  
3. When using an automatic charger, refer to the charger manufac-  
turer's instructions for recharging. When using a constant current  
charger, use the following guidelines for recharging.  
90  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Battery  
Battery Charging (Sealed Battery)  
Always verify battery condition before and 1-2 hours after the end of  
charging.  
Charge Time  
State of  
Charge  
(Using constant current  
Voltage  
Action  
charger @ standard amps  
specified on top of battery)  
100%  
12.8-13.0 volts  
None, check at 3  
mos. from date of  
manufacture  
None required  
75%-100%  
12.5-12.8 volts  
May need slight  
charge, if no  
3-6 hours  
charge given,  
check in 3 months  
50%-75%  
25%-50%  
12.0-12.5 volts  
11.5-12.0 volts  
Needs charge  
Needs charge  
5-11 hours  
At least 13 hours,  
verify state of charge  
0%-25%  
11.5 volts or less Needs charge with  
desulfating charger  
At least 20 hours  
91  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Cleaning and Storage  
Washing the Vehicle  
Keeping your Polaris vehicle clean will not only improve its appearance  
but it can also extend the life of various components.  
NOTICE: High water pressure may damage components. Polaris recommends  
washing the vehicle by hand or with a garden hose, using mild soap.  
Certain products, including insect repellents and chemicals, will  
damage plastic surfaces. Do not allow these types of products to  
contact the vehicle.  
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  
• Avoid the use of harsh cleaners, which can scratch the finish.  
• Do not use a power washer to clean the vehicle.  
• Do not use medium to heavy duty compounds on the finish.  
• Always use clean cloths and pads for cleaning and polishing. Old or  
reused cloths and pads may contain dirt particles that will scratch the  
finish.  
92  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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 follow-  
ing items:  
• Wheel bearings  
• Radiator  
• Transmission seals  
• Brakes  
• Electrical components/wiring  
• Switches and controls  
• Cab and body panels  
• Labels and decals  
If an informational or graphic label becomes illegible or comes off, con-  
tact your Polaris dealer to purchase a replacement. Replacement safety  
labels are provided by Polaris at no charge.  
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  
• Avoid the use of automotive products, some of which can scratch the  
finish of your vehicle.  
• 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.  
93  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Cleaning and Storage  
Chrome Wheel Care (if equipped)  
Proper maintenance will protect chrome wheels from corrosion, pre-  
serve wheel life and ensure a “like new” appearance for many years.  
Chrome wheels exposed to road salt (or salt in the air in coastal areas)  
are more susceptible to corrosion if not properly cleaned. Clean chrome  
wheels more often if they're exposed to salt or other corrosive elements.  
1. Wash chrome wheels frequently. Use a mild detergent. 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 pol-  
ished 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 out-  
lined above.  
94  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Cleaning and Storage  
Storage Tips  
NOTICE: Starting the engine during the storage period will disturb the  
protective film created by fogging and damage could occur. Never  
start the engine during the storage period.  
Clean the Exterior  
Make any necessary repairs and clean the vehicle as recommended. See  
page 92.  
Stabilize the Fuel  
1. Fill the fuel tank.  
2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer.  
Follow the instructions on the container for the recommended  
amount. 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 53.  
Air Filter / Air Box  
1. Inspect and clean (or replace) the pre-cleaner and air filter.  
2. Clean the air box.  
3. Clean or replace the breather filter.  
4. Drain the sediment tube.  
95  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Cleaning and Storage  
Storage Tips  
Fluid Levels  
Inspect the fluid levels. Change fluids as recommended in the Periodic  
Maintenance Chart beginning on page 47.  
• Demand drive unit (front gearcase)  
• Transmission  
• Brake fluid (change every two years and any time the fluid looks dark  
or contaminated)  
• Coolant (test strength/fill)  
Fog the Engine  
1. Treat the fuel system with Polaris Carbon Clean. See page 95.  
2. Support the front end of the machine so the engine is level or tilted  
slightly rearward.  
3. Remove the spark plug. Pour 2-3 tablespoons (30-40 ml) of engine  
oil into the hole.  
Tip: 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 electric start. Oil will  
be forced in and around the piston rings and ring lands, coating the  
cylinder with a protective film of fresh oil.  
7. If Polaris fuel system additive is not used, the fuel tank, fuel lines,  
and carburetor should be completely drained of gasoline.  
8. To eliminate any fuel remaining in the carburetor, run the engine  
until it stops.  
96  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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 47.  
Battery Storage  
See pages 89-90 for storage and charging procedures.  
Storage Area/Covers  
Set the tire pressure and safely support the vehicle with the tires slightly  
off the ground. Be sure the storage area is well ventilated. Cover the  
vehicle with a genuine Polaris cover. Do not use plastic or coated mate-  
rials. They do not allow enough ventilation to prevent condensation, and  
may promote corrosion and oxidation.  
97  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Transporting the Vehicle  
Follow these procedures when  
transporting the vehicle.  
1. Stop the engine.  
2. Place the transmission in  
gear.  
3. Lock the parking brake.  
4. Turn the fuel valve off.  
5. Secure the fuel cap, oil cap  
and seat.  
6. Remove the key to prevent  
loss during transporting.  
7. Always tie the frame of the  
vehicle to the transporting  
unit securely with suitable  
straps or rope. Do not  
attach tie straps to the front  
A-arm bolt pockets, racks  
or handlebars.  
98  
Download from Www.Somanuals.com. All Manuals Search And Download.  
POLARIS PRODUCTS  
Part  
Number  
Description  
Engine Lubricant  
2870791  
2876244  
2876245  
Fogging Oil (12 oz. Aerosol)  
PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt./.95 l)  
PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal./3.8 l)  
Gearcase / Transmission Lubricants  
Premium AGL Synthetic Gearcase Lubricant (qt./.95 l)  
Premium AGL Synthetic Gearcase Lube (gal./3.8 l)  
Premium ATV Angle Drive Fluid (8 oz./237 ml)  
Premium ATV Angle Drive Fluid (2.5 gal./9.5 l)  
Pump for Gallon (3.8 l) Jug  
2873602  
2873603  
2871653  
2872276  
2870465  
2876251  
Demand Drive LT Premium Fluid (8 oz./237 ml)  
Coolant  
2871323  
2871534  
60/40 Coolant (gal./3.8 l)  
60/40 Coolant (qt./.95 l)  
Grease / Specialized Lubricants  
2871312  
2871322  
2871423  
2871460  
2871515  
2871551  
2871329  
2872073  
2872348  
Grease Gun Kit, Premium All Season  
Premium All Season Grease (3 oz./89 ml cartridge)  
Premium All Season Grease (14 oz./414 ml cartridge)  
Starter Drive Grease  
Premium U-Joint Lube (3 oz./89 ml cartridge)  
Premium U-Joint Lube (14 oz./414 ml cartridge)  
Dielectric Grease (NyogelTM  
)
Chain Lube, Aerosol (6.25 oz./185 ml)  
Chain Lube, Aerosol (16 oz./473 ml)  
Additives / Miscellaneous  
Carbon Clean Plus  
2871326  
2870652  
2872189  
2871956  
2859044  
Fuel Stabilizer  
DOT 4 Brake Fluid  
LoctiteTM 565 Thread Sealant  
Polaris Battery TenderTM Charger  
99  
Download from Www.Somanuals.com. All Manuals Search And Download.  
TROUBLESHOOTING  
Drive Belt Wear/Burn  
Possible Cause  
Solution  
Starting out going up a  
steep incline  
Use low range (if equipped) or turn around using the K-  
turn (see page 39).  
Driving at low RPM or  
Drive at a higher speed or use low range (if equipped)  
ground speed (3-7 MPH) more frequently.  
Insufficient warm-up at  
low ambient tempera-  
tures  
Warm the engine at least 5 minutes. With the transmission  
in neutral, advance the throttle to about 1/8 throttle in  
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 (if equipped).  
Utility use/plowing  
Use low range only (if equipped).  
Stuck in mud or snow  
Shift the transmission to low range (if equipped). Care-  
fully 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  
Belt slippage from water Dry out the PVT. See page 85. Inspect clutch seals for  
or snow ingestion into the damage if repeated leaking occurs.  
PVT system  
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 (48  
km/h) for one mile (1.6 km). Operate 5 miles (8 km) or  
more when temperature is below freezing.  
Wrong or missing belt  
Improper break-in  
Install the recommended belt.  
Always break in a new belt and/or clutch. See page 29.  
100  
Download from Www.Somanuals.com. All Manuals Search And Download.  
TROUBLESHOOTING  
Engine Doesn't Turn Over  
Possible Cause  
Solution  
Tripped circuit breaker  
Low battery voltage  
Reset the breaker  
Recharge the battery to 12.8 VDC  
Check all connections and tighten  
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  
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  
Overuse of choke  
Drain the fuel system and refuel  
Turn the fuel valve on  
Replace with fresh recommended fuel  
Inspect plugs and replace if necessary  
Inspect plugs, verify stop switch is up  
Inspect, clean and/or replace spark plugs  
Replace the filter  
Clogged fuel filter  
Water or fuel in crankcase  
Low battery voltage  
Immediately see your Polaris dealer  
Recharge the battery to 12.8 VDC  
See your dealer  
Mechanical failure  
Engine Backfires  
Possible Cause  
Solution  
Weak spark from spark plug  
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 fresh recommended fuel  
See your dealer  
See your dealer  
Mechanical failure  
See your dealer  
Exhaust leaks  
Replace exhaust seals  
101  
Download from Www.Somanuals.com. All Manuals Search And Download.  
TROUBLESHOOTING  
Engine Pings or Knocks  
Possible Cause  
Solution  
Poor quality or low octane fuel  
Incorrect ignition timing  
Replace with recommended fuel  
See your dealer  
Incorrect spark plug gap or heat range  
Idle set too low  
Set gap to specs or replace plugs  
Adjust idle speed  
Engine Runs Irregularly, Stalls or Misfires  
Possible Cause  
Solution  
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  
Inspect, clean and/or replace spark plugs  
See your 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 tank vent line  
Incorrect fuel  
Replace with recommended fuel  
Inspect and clean or replace  
See your dealer  
Clogged air filter  
Reverse speed limiter malfunction  
Electronic throttle control malfunction  
Other mechanical failure  
See your dealer  
See your dealer  
Possible Lean Fuel 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 dealer  
Possible Rich Fuel 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 dealer  
102  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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 is present in fuel  
Replace with new fuel  
Overuse of choke  
Inspect, clean and/or replace spark plugs  
Inspect, clean and/or replace spark plugs  
See your 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 plug  
Check all connections and tighten  
Recharge the battery to 12.8 VDC  
Replace with fresh recommended fuel  
Inspect and clean or replace  
See your dealer  
Incorrect fuel  
Clogged air filter  
Reverse speed limiter malfunction  
Electronic throttle control malfunction  
Other mechanical failure  
Overheated engine  
See your dealer  
See your dealer  
Clean radiator screen and core if  
equipped  
Clean engine exterior  
See your Polaris dealer  
103  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SPECIFICATIONS  
Scrambler 500 4X4 International  
Maximum Weight Capacity  
275 lbs. (125 kg) (includes weight of opera-  
tor, cargo and accessories)  
Dry Weight  
Fuel Capacity  
570 lbs. (258.5 kg)  
4 gal. (15.1 l)  
Engine Oil Capacity  
Transmission Oil  
2 qts. (1.9 l)  
32 oz. (946 ml)  
Demand Drive Fluid Capacity  
Coolant  
Rear Rack Capacity (Accessory)  
Hitch Tongue Weight Capacity  
9 oz. (265 ml)  
2.25 qts. (2.13 l)  
60 lbs. (27.2 kg) (Maximum)  
85 lbs. (38.6 kg) (Rear rack capacity and  
tongue weight not to exceed 60 lbs./27.2 kg)  
Hitch Towing Rating  
Unbraked Trailer Towing Capacity*  
Overall Length  
Overall Width  
850 lbs. (385.6 kg)  
1210 lbs. (549 kg)  
75 in. (190.5 cm)  
45 in. (114 cm)  
Overall Height  
Wheelbase  
49 in. (124.5 cm)  
48.5 in. (123 cm)  
Ground Clearance  
Minimum Turning Radius  
Engine Model Number/Type  
Lubrication  
4.75 in. (12 cm)  
65 in. (165 cm) unloaded  
EH50PLE-129 / 4 Cycle, Single Cylinder  
Dry sump  
Engine Cooling  
Displacement  
Liquid  
498 cc  
Bore x Stroke  
92 x 75  
Alternator Output  
Compression Ratio  
Carburetor  
250w @5000 rpm  
10.2:1  
BST 40  
Pilot Jet  
37.5  
Main Jet  
155  
Needle Jet  
X-6M  
Jet Needle  
6MGHI194-4  
Pilot Air Jet  
1.3  
Pilot Screw  
3 turns  
Ignition System  
Ignition Timing  
Idle RPM  
CDI  
30° +/- 2° @ 5000 RPM  
1350  
Spark Plug / Gap  
BKR6E / .036 in. (.9 mm)  
* Based on EU Directive 76/432/EC  
104  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SPECIFICATIONS  
Scrambler 500 4X4 International  
Driving System Type  
Automatic PVT (Polaris Variable Transmission)  
Shift Type  
Side Lever (F/N/R)  
Gear Reduction, Reverse  
Gear Reduction, Forward  
Drive Ratio, Front  
Drive Ratio, Final  
Drive Chain  
4.74:1  
3.06:1  
3.818:1  
2.77:1  
520 O-Ring  
Tires/Pressure, Front  
Tires/Pressure, Rear  
Front Suspension  
Rear Suspension  
Shock Adjustment  
Hand Brake  
Foot Brake  
Brake, Parking  
Headlight  
23 x 7-10 (4 psi/27.6 kPa)  
22 x 11-10 (3 psi/20.7 kPa)  
MacPherson strut with 8.2" (21 cm) travel  
Progressive rate with 10.5" (26.7 cm) travel  
CAM  
Single-Control Hydraulic Disc, All Wheel  
Foot-Activated Hydraulic Disc, All Wheel  
Hydraulic lock, all wheel  
Single Beam 60w  
Taillights  
12V 8.26W  
Brake Light  
12V 26.9W  
Battery  
12V 14AH  
Indicators  
High Beam/Turn Signals/High Temp/Neutral/  
Reverse  
Jetting Chart  
ALTITUDE  
AMBIENT TEMPERATURE  
Meters (Feet)  
Below 40° F  
40°F and above  
(5°C and above)  
(Below 5° C)  
0-1800 (0-6000)  
160  
155  
1800-3700 (6000-12000)  
152.5  
147.5  
Clutching Chart  
Altitude  
Shift  
Drive Clutch  
Spring  
Driven Clutch  
Helix/Spring/  
Meters (Feet)  
Weight  
Spring  
Setting  
0-1800  
(0-6000)  
25-52  
5632391  
Blue/Green  
7041157  
Black  
7041782  
40°  
5131446  
2+2  
1800 & above  
(6000 & above)  
25-48  
5630709  
Blue/Green  
7041157  
Black  
7041782  
40°  
5131446  
2+2  
105  
Download from Www.Somanuals.com. All Manuals Search And Download.  
DECLARATION OF CONFORMITY  
Polaris Industries Inc.,  
2100 Hwy 55, Medina, MN 55340 U.S.A.  
Telephone 763-542-0500  
We, Polaris Industries Inc., declare that the vehicles listed below conform to the  
essential health and safety requirements applicable to off-road all-terrain vehicles.  
APPLICABLE EUROPEAN DIRECTIVES  
TEST / EVALUATION METHODS  
98/37/EC as amended (Machinery Directive)  
EN 1050 hazard analysis  
CD 77/311/EEC driver-perceived noise level  
2004/108/EC as amended (EMC Directive)  
CISPR 12:2001  
CAN/CSA-C108.4-M92  
EN 55012:2002  
EN 61000-6-2:2001  
PRODUCT IDENTIFICATION  
VEHICLE SERIES  
TRADE NAME  
MODEL  
YEARS  
SOUND  
PRESSURE  
dB (A)  
___KA05__  
___KA09__  
___FA09__  
___VA17__  
___PB20__  
___BA32__  
___CA32__  
___BA50__  
___GJ45__  
___GJ52__, ___GP52__  
___LH27__  
___LH46__  
___MN50__  
OUTLAW 50  
OUTLAW 90  
SPORTSMAN 90  
RZR 170  
PHOENIX 200  
TRAIL BLAZER 330  
TRAIL BOSS 330  
SCRAMBLER 500  
OUTLAW 450  
2008, 2009, 2010  
2008, 2009, 2010  
2008, 2009, 2010  
2009, 2010  
76.8  
76.8  
76.8  
81.3  
76.8  
76.8  
76.8  
79.6  
80.7  
80.7  
81.1  
80.2  
80.4  
80.8  
77.2  
83.6  
77.2  
80.1  
80.4  
76.5  
76.5  
76.5  
76.5  
76.5  
85.8  
2008, 2009, 2010  
2008, 2009, 2010  
2008, 2009, 2010  
2008, 2009, 2010  
2008, 2009, 2010  
2008, 2009, 2010  
2008, 2009, 2010  
2008, 2009, 2010  
2008, 2009, 2010  
2009, 2010  
OUTLAW 525  
SPORTSMAN 300  
SPORTSMAN 400  
SPORTSMAN 500 EFI  
SPORTSMAN 550 EFI  
___ZN55__ ___ZX55__  
___TN55__, ___DN55__ SPORTSMAN X2/TOURING 550 2010  
___MN76__ SPORTSMAN 800 2008, 2009, 2010  
___TN85__, ___DN85__ SPORTSMAN X2/TOURING 850 2010  
___CL76__  
___ZN85__, ___ZX85__  
SPORTSMAN 800 6X6  
SPORTSMAN 850 EFI  
2009, 2010  
2009, 2010  
2009, 2010  
2010  
2010  
2010  
___RH50__, ___HH50__ RANGER 500 EFI 4X4  
___HH76__  
___WH76__  
___HR__  
___HY__  
___VH76__  
RANGER 800 EFI 4X4  
RANGER 800 EFI CREW  
RANGER 800 6X6  
RANGER HD 800 4X4  
RANGER RZR  
2010  
2008, 2009, 2010  
Authorized Signatory:  
_________  
Alexander A. Kennedy, Product Compliance  
Polaris Industries Inc., Engineering Operations  
301 5th Avenue SW, Roseau, MN 56751  
106  
Download from Www.Somanuals.com. All Manuals Search And Download.  
WARRANTY  
LIMITED WARRANTY  
Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a TWO YEAR  
LIMITED WARRANTY on all components of the Polaris vehicle against defects in  
material or workmanship. This warranty covers the parts and labor charges for repair or  
replacement of defective parts which are covered by this warranty. This warranty begins  
on the date of purchase. This warranty is transferable to another consumer during the  
warranty period through a Polaris dealer.  
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 entitle-  
ment. 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 VEHICLE IS REGISTERED WITH POLARIS.  
Initial dealer preparation and set-up of your vehcile is very important in ensuring trou-  
ble-free operation. Purchasing a machine in the crate or without proper dealer set-up will  
void your warranty coverage.  
107  
Download from Www.Somanuals.com. All Manuals Search And Download.  
WARRANTY  
WARRANTY COVERAGE AND EXCLUSIONS:  
LIMITATIONS OF WARRANTIES AND REMEDIES  
The Polaris limited warranty excludes any failures that are not caused by a defect in  
material or workmanship. This warranty does not cover accidental damage, normal wear  
and tear, abuse or improper handling. This warranty also does not cover any vehicle that  
has been altered structurally, modified, neglected, improperly maintained, used for rac-  
ing, or used for purposes other than for which it was manufactured, or for any damages  
which occur during trailer transit or as a result of unauthorized service or the use of  
unauthorized parts. In addition, this 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 vehicle due to fire, explosions or any other cause beyond  
Polaris' control.  
Warranty does not apply to parts exposed to friction surfaces, stresses, environmental  
conditions and/or contamination for which they were not designed or not intended,  
including but not limited to the following items:  
Wheels and tires  
Finished and unfinished surfaces  
Carburetor/Throttle body components  
Engine components  
Suspension components  
Brake components  
Seat components  
Clutches and components  
Steering components  
Batteries  
Drive belts  
Hydraulic components  
Circuit breakers/Fuses  
Electronic components  
Light bulbs/Sealed beam lamps  
Warranty applies to the product only and does not allow for coverage of personal loss.  
Some items are considered "consumable," meaning they are considered part of normal  
maintenance or part of completing an effective repair. The following items are excluded  
from warranty coverage in the event of a warranty claim:  
Spark Plugs  
Filters  
Fuel  
Sealants  
Hotel fees  
Towing charges  
Mileage  
Rentals/Loss of product use  
Lubricants such as oil, grease, etc.  
Batteries (unless defective)  
Cosmetic damage/repair  
Coolants  
Meals  
Shipping/ handling fees  
Product pick-up/delivery  
Loss of vacation/personal time  
108  
Download from Www.Somanuals.com. All Manuals Search And Download.  
WARRANTY  
LIMITATIONS OF WARRANTIES AND REMEDIES  
This warranty also excludes failures resulting from improper lubrication; improper  
engine timing; improper fuel; surface imperfections caused by external stress, heat, cold  
or contamination; operator error or abuse; improper component alignment, tension,  
adjustment or altitude compensation; failure due to snow, water, dirt or other foreign  
substance ingestion/contamination; improper maintenance; modified components; use  
of aftermarket components resulting in failure; unauthorized repairs; repairs made after  
the warranty period expires or by an unauthorized repair center; use of the product in  
competition or for commercial purposes. Warranty will not apply to any product which  
has been damaged by abuse, accident, fire or any other casualty not determined a defect  
of materials or workmanship.  
This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that  
are not compatible with the vehicle. 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 DESCRIP-  
TION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR  
ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE.  
Some states do not permit the exclusion or limitation of incidental or consequential  
damages or implied warranties, so the above limitations or exclusions may not apply to  
you if inconsistent with controlling state law.  
109  
Download from Www.Somanuals.com. All Manuals Search And Download.  
WARRANTY  
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE  
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-  
TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE TWO  
YEAR WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS  
WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limi-  
tations on how long an implied warranty lasts, so the above limitation may not apply to  
you if inconsistent with controlling state law.  
HOW TO OBTAIN WARRANTY SERVICE  
If your vehicle requires warranty service, you must take it to a Polaris dealer authorized  
to repair Polaris vehicles. When requesting warranty service you must present your copy  
of the Warranty Registration form to the dealer. (THE COST OF TRANSPORTATION  
TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests that  
you use your original selling dealer; however, you may use any Polaris Servicing Dealer  
to perform warranty service.  
Please work with your dealer to resolve any warranty issues. Should your dealer require  
any additional assistance they will contact the appropriate person 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.  
110  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE LOG  
Present this section of your manual to your dealer each time your vehicle is serviced.  
This will provide you and future owners with an accurate log of maintenance and ser-  
vices performed.  
DATE  
MILES (KM)  
OR HOURS  
TECHNICIAN  
SERVICE PERFORMED / COMMENTS  
111  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE LOG  
DATE  
MILES (KM)  
OR HOURS  
TECHNICIAN  
SERVICE PERFORMED / COMMENTS  
112  
Download from Www.Somanuals.com. All Manuals Search And Download.  
INDEX  
A
D
Age Restrictions . . . . . . . . . . . . . . . . . 5  
Air Filter . . . . . . . . . . . . . . . . . . . . . . 68  
All Wheel Drive Switch . . . . . . . . . . 21  
All Wheel Drive System. . . . . . . . . . 28  
Demand Drive Fluid . . . . . . . . . . . . . 58  
Drive Belt Wear/Burn. . . . . . . . . . . 100  
Drive Chain. . . . . . . . . . . . . . . . . 71-73  
Drive Chain Lubrication. . . . . . . . . . 71  
Drive Chain Slack. . . . . . . . . . . . 72-73  
Drivetrain Break-In. . . . . . . . . . . . . . 29  
Driving Downhill . . . . . . . . . . . . . . . 38  
Driving in Reverse . . . . . . . . . . . . . . 42  
Driving on a Sidehill. . . . . . . . . . . . . 37  
Driving on Slippery Surfaces . . . . . . 35  
Driving Over Obstacles . . . . . . . . . . 41  
Driving Procedures . . . . . . . . . . . . . . 33  
Driving Through Water . . . . . . . . . . 40  
Driving Uphill. . . . . . . . . . . . . . . . . . 36  
B
Battery . . . . . . . . . . . . . . . . . . . . 86-91  
Charging (Conventional) . . . . . . . 90  
Charging (Sealed) . . . . . . . . . 90-91  
Fluid (Conventional) . . . . . . . . . . 89  
Installation . . . . . . . . . . . . . . . . . . 88  
Removal . . . . . . . . . . . . . . . . . . . . 87  
Storage . . . . . . . . . . . . . . . . . . . . . 89  
Boots . . . . . . . . . . . . . . . . . . . . . . . . . . 9  
Brake Fluid . . . . . . . . . . . . . . . . . 59-60  
Brake Inspections . . . . . . . . . . . . . . . 61  
Brake, Foot . . . . . . . . . . . . . . . . . . . . 24  
Brake, Hand . . . . . . . . . . . . . . . . . . . 24  
Brake, Parking . . . . . . . . . . . . . . . . . 25  
Brakes . . . . . . . . . . . . . . . . . . 24-25, 61  
Break-In Period. . . . . . . . . . . . . . . . . 29  
Breather Filter. . . . . . . . . . . . . . . . . . 68  
E
Electromagnetic Interference . . . . . . 46  
Engine Break-In . . . . . . . . . . . . . . . . 29  
Engine Fogging. . . . . . . . . . . . . . . . . 96  
Engine Idle RPM Adjustment. . . . . . 70  
Engine Oil. . . . . . . . . . . . . . . . . . . . . 52  
Engine Stop Switch. . . . . . . . . . . . . . 20  
Equipment Modifications . . . . . . . . 5, 7  
Exhaust Emission Control System . . 46  
Eye Protection. . . . . . . . . . . . . . . . . . . 9  
C
Carburetor . . . . . . . . . . . . . . . . . . . . . 70  
Carburetor Adjustment . . . . . . . . . . . 70  
Cargo. . . . . . . . . . . . . . . . . . . . . . 44-45  
Choke . . . . . . . . . . . . . . . . . . . . . . . . 26  
Chrome Wheel Care . . . . . . . . . . . . . 94  
Cleaning and Storage . . . . . . . . . 92-97  
Clothing . . . . . . . . . . . . . . . . . . . . . . . 9  
Clutching Chart. . . . . . . . . . . . . . . . 105  
Coolant Bottle. . . . . . . . . . . . . . . . . . 74  
Coolant, Radiator . . . . . . . . . . . . . . . 75  
Cooling System. . . . . . . . . . . . . . 74-75  
Corrosion Removal, Chrome . . . . . . 94  
F
Fluid, Brake . . . . . . . . . . . . . . . . 59-60  
Fluid, Demand Drive . . . . . . . . . . . . 58  
Foot Brake . . . . . . . . . . . . . . . . . . . . 24  
Front Gearcase Fluid. . . . . . . . . . . . . 58  
Fuel Filter . . . . . . . . . . . . . . . . . . . . . 26  
Fuel Safety . . . . . . . . . . . . . . . . . . . . 15  
Fuel Tank Cap. . . . . . . . . . . . . . . . . . 26  
Fuel Valve. . . . . . . . . . . . . . . . . . . . . 26  
113  
Download from Www.Somanuals.com. All Manuals Search And Download.  
INDEX  
G
N
Gasoline Handling . . . . . . . . . . . . . . 15  
Gear Selector . . . . . . . . . . . . . . . . . . 25  
Gloves . . . . . . . . . . . . . . . . . . . . . . . . 9  
Noise Emission Control System . . . . 46  
O
Oil, Engine. . . . . . . . . . . . . . . . . . . . . 52  
Oil, Transmission. . . . . . . . . . . . . 56-57  
Oil and Filter Change . . . . . . . . . 53-55  
Oil Level, Engine. . . . . . . . . . . . . . . . 52  
Oil Pump Priming . . . . . . . . . . . . . . . 55  
Oil Recommendations . . . . . . . . . . . . 52  
Operator Safety . . . . . . . . . . . . . . 10-15  
Override Switch. . . . . . . . . . . . . . . . . 20  
H
Handlebar Adjustment. . . . . . . . . . . 69  
Hauling Cargo . . . . . . . . . . . . . . . 44-45  
Hazard Switch . . . . . . . . . . . . . . . . . 21  
Headlamp Replacement. . . . . . . . . . 77  
Headlight Beam Adjustment . . . . . . 76  
Headlight Switch . . . . . . . . . . . . . . . 21  
Helmet . . . . . . . . . . . . . . . . . . . . . . . . 8  
Horn Switch. . . . . . . . . . . . . . . . . . . 21  
P
Parking Brake . . . . . . . . . . . . . . . . . . 25  
Parking on an Incline. . . . . . . . . . . . . 43  
Periodic Maintenance Chart . . . . 47-50  
Polaris Product List . . . . . . . . . . . . . . 99  
Polishing the Vehicle. . . . . . . . . . . . . 93  
Pre-Ride Checklist. . . . . . . . . . . . . . . 30  
PVT Break-In . . . . . . . . . . . . . . . . . . 29  
PVT Drying . . . . . . . . . . . . . . . . . . . . 85  
PVT System. . . . . . . . . . . . . . . . 83- 85  
I
Idle RPM Adjustment . . . . . . . . . . . 70  
Immersion . . . . . . . . . . . . . . . . . . . . 81  
Indicator Lights . . . . . . . . . . . . . . . . 22  
J
Jetting Chart. . . . . . . . . . . . . . . . . . 105  
K
R
Key Switch. . . . . . . . . . . . . . . . . . . . 21  
K-Turn . . . . . . . . . . . . . . . . . . . . . . . 39  
Reverse Operation . . . . . . . . . . . . . . . 42  
Riding Gear . . . . . . . . . . . . . . . . . . . 8-9  
L
S
Lights . . . . . . . . . . . . . . . . . . . . . 76-78  
Headlamp Replacement . . . . . . . 77  
Headlight Beam Adjustment. . . . 76  
Indicator Lamp Replacement . . . 78  
Taillight/Brakelight Replacement 78  
Load Distribution. . . . . . . . . . . . . . . 45  
Lubrication Guide . . . . . . . . . . . . . . 51  
Safety Labels . . . . . . . . . . . . . . . . 16-19  
"No Passenger" Warning . . . . . . . 18  
4X4 Caution . . . . . . . . . . . . . . . . . 19  
Age 16 Warning . . . . . . . . . . . . . . 19  
Clutch Cover Warning . . . . . . . . . 19  
Discretionary Warning . . . . . . . . . 17  
General Warning. . . . . . . . . . . . . . 16  
Reverse Override Warning . . . . . . 19  
Tire Pressure/Load Warning. . . . . 18  
Safety Training . . . . . . . . . . . . . . . . . . 5  
Severe Use. . . . . . . . . . . . . . . . . . . . . 47  
M
Maintenance Chart. . . . . . . . . . . . 47-50  
Mirrors. . . . . . . . . . . . . . . . . . . . . . . 22  
Modifications. . . . . . . . . . . . . . . . . 5, 7  
114  
Download from Www.Somanuals.com. All Manuals Search And Download.  
INDEX  
S
T
Side Panel Removal . . . . . . . . . . . . . 61  
Sidehilling. . . . . . . . . . . . . . . . . . . . . 37  
Signal Words. . . . . . . . . . . . . . . . . . . . 4  
Spark Arrestor. . . . . . . . . . . . . . . . . . 82  
Spark Arrestor Requirements . . . . . . 46  
Spark Plugs . . . . . . . . . . . . . . . . . 79-80  
Spring Preload, Rear. . . . . . . . . . . . . 63  
Starting the Engine . . . . . . . . . . . 31-32  
Steering Assembly . . . . . . . . . . . . . . 63  
Steering Lock . . . . . . . . . . . . . . . . . . 27  
Stop Switch. . . . . . . . . . . . . . . . . . . . 20  
Storage . . . . . . . . . . . . . . . . . . . . 92-97  
Suspension Adjustments, Rear . . . . . 63  
Switches . . . . . . . . . . . . . . . . . . . 20-21  
All Wheel Drive Switch. . . . . . . . 21  
Engine Stop Switch . . . . . . . . . . . 20  
Hazard Switch . . . . . . . . . . . . . . . 21  
Headlight Switch . . . . . . . . . . . . . 21  
Horn Switch . . . . . . . . . . . . . . . . . 21  
Main Key Switch . . . . . . . . . . . . . 21  
Override Switch . . . . . . . . . . . . . . 20  
Turn Signal Switch. . . . . . . . . . . . 21  
Throttle Cable Freeplay . . . . . . . . . . 64  
Throttle Lever . . . . . . . . . . . . . . . . . . 23  
Tire Tread Depth. . . . . . . . . . . . . . . . 65  
Tires . . . . . . . . . . . . . . . . . . . . . . 65-67  
Front Wheel Hub Tightening. . . . 65  
Tread Depth . . . . . . . . . . . . . . . . . 65  
Wheel Installation . . . . . . . . . . . . 66  
Wheel Nut Torque . . . . . . . . . . . . 67  
Wheel Removal . . . . . . . . . . . . . . 66  
Toe Alignment . . . . . . . . . . . . . . . . . 62  
Towing Loads . . . . . . . . . . . . . . . . . . 45  
Training, Safety . . . . . . . . . . . . . . . . . 5  
Transmission Oil. . . . . . . . . . . . . 56-57  
Transporting the Vehicle . . . . . . . . . 98  
Turn Signal Switch . . . . . . . . . . . . . . 21  
Turning Around on a Hill . . . . . . . . . 39  
Turning the Vehicle . . . . . . . . . . . . . 34  
V
Vehicle Identification Numbers . . . . . 6  
Vehicle Immersion . . . . . . . . . . . . . . 81  
W
Warning Symbols . . . . . . . . . . . . . . . . 4  
Washing the Vehicle. . . . . . . . . . 92-93  
Wheel Hub Tightening . . . . . . . . . . . 65  
Wheel Installation. . . . . . . . . . . . . . . 66  
Wheel Nut Torque Specifications. . . 67  
Wheel Removal . . . . . . . . . . . . . . . . 66  
115  
Download from Www.Somanuals.com. All Manuals Search And Download.  

Peavey Musical Instrument Amplifier Pro 50 User Manual
Philips Bottle Warmer SCF600 11 User Manual
Philips Stereo System SDV2710 27 User Manual
Philips Welding System TS2519C User Manual
PoGo Products Stereo System AM FM Radio Recorder Voice Recorder MP3WMA Player User Manual
Polaroid Digital Camera HD Professional Action Camera User Manual
Porter Cable Saw 4210 4212 User Manual
Portsmith Crib PS6PM5C 10 User Manual
ProForm Treadmill PFTL989081 User Manual
PYLE Audio Headphones PBT30M User Manual