Polaris Offroad Vehicle 500 2X4 International User Manual

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WELCOME

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

wide family of Polaris owners. We proudly produce an exciting line of

utility and recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

• Quadricycles

• 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.polarisin-

dustries.com.

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POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus-

tries Inc.

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 Taiwan

2009 Scrambler 500 2X4 International Owner’s Manual

P/N 9922077

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TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Features and Controls . . . . . . . . . . . . . . . . . . . 22

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Emission Control Systems . . . . . . . . . . . . . . . 49

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 102

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 104

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 105

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 111

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

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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.

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INTRODUCTION

WARNING

Failure to heed the warnings and safety precautions contained in this manual

can result in severe injury or death. This 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 this owner’s manual. Understand all safety warnings, precautions and

operating procedures before operating the vehicle.

• Never operate this vehicle without proper instruction. Take a training course.

• This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone

under 16 years of age.

• This vehicle is approved for OFF-ROAD TOWING ONLY. Operating a

Quadricycle/trailer combination on public roads is prohibited.

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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. 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: ___________________________________________________________

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SAFETY

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 your vehicle from a party other than a Polaris dealer,

please request free safety training from any authorized Polaris dealer.

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) mow-

ers, blades, tires, sprayers and large racks may change vehicle handling.

Use only Polaris-approved accessories. Know their function and effect

on the vehicle.

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SAFETY

Safe Riding Gear

Always wear protective clothing to reduce the chance of injury.

Eye Protection

Long

Sleeves

Helmet

Gloves

Long Pants

Boots

Helmet

Always wear a helmet that meets or exceeds established safety stan-

dards.

Approved helmets in the USA and Canada bear a U.S. Department of

Transportation (DOT) label.

Approved helmets in Europe, Asia and Oceania

bear the ECE 22.05 label. The ECE mark consists

of a circle surrounding the letter E, followed by the

distinguishing number of the country which has

granted approval. The approval number and serial

number will also be displayed on the label.

051039

0006.31

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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.

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SAFETY

Operator 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.

Read and understand all warnings, cautions and

operating procedures in this manual and on the

safety labels before operating this 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 this vehicle unless

they have read and understand 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.

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SAFETY

Operator Safety

Handling Gasoline

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

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

area.

• Do not smoke or allow open flames or sparks in or near the area where

refueling is performed or where gasoline is stored.

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

• 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.

Never start the engine or let it run in an enclosed area. Operate this vehicle only

outdoors or in well-ventilated areas.

Always inspect your 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 33.

Always wear an approved helmet that fits

properly. Wear eye protection (goggles or face

shield), gloves, boots, long sleeves and long

pants.

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SAFETY

Operator Safety

Never consume alcohol or drugs before

or while operating this vehicle.

Keep both hands on the handlebars. Keep

both feet on the footrests.

Never carry a passenger. The purpose of

the long seat is to allow the operator to

shift position as needed during operation. It

is not intended for carrying passengers.

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SAFETY

Operator Safety

Never carry a passenger on the rear rack.

Ejection from the vehicle or contact with

moving components can result in serious

injury or death.

Operating on paved surfaces may seriously affect the handling and control of

the Quadricycle and could result in loss of control, accident and/or injury. Avoid

sudden turns or swift movement of the handlebars.

Never operate at excessive speeds. Travel

and turn at speeds appropriate for the

terrain, visibility, operating conditions and

your experience.

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SAFETY

Operator Safety

Always follow the procedures outlined in this

manual for turning. Never turn sharply at

excessive speeds, which can lead to vehicle

overturn. See page 37.

Never attempt jumps or other stunts.

Always follow the procedures outlined in

this manual for driving through water.

Never drive through deep or fast-flowing

water. See page 43.

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SAFETY

Operator Safety

Always follow the procedures outlined in this

manual for driving on hills. See page 39. Never

operate on hills too steep for this 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 driving downhill and for braking on

hills. See page 41.

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 42.

Always follow the procedures outlined in this

manual for crossing the side of a hill. See page

40. Never attempt to turn this vehicle around on

any hill until you've mastered (on level ground)

the turning technique outlined in this manual.

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SAFETY

Operator Safety

Always use the size and type of tires

specified for your vehicle. Maintain the

proper tire pressure.

Always travel slowly when operating on

unfamiliar terrain. Use extra caution.

Always follow the procedures outlined in this manual for driving in reverse. See

page 45.

Use caution when operating on rough, slippery

or loose terrain.

Always follow the procedures outlined in this manual for operating over

obstacles. See page 44.

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

38.

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SAFETY

Operator Safety

Never operate this vehicle on a frozen body of water.

Never modify a Quadricycle through improper installation or use of accessories.

Never exceed the stated load capacity for your vehicle. Cargo must be properly

distributed and securely attached. Reduce speed and follow the instructions in

this manual for carrying cargo or towing. Allow a greater distance for braking.

If this 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.

Hot components can cause serious burns and fire. Do not touch hot exhaust

system components. Always keep combustible materials away from the exhaust

system.

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

unauthorized use or accidental starting.

For more information about Quadricycle safety, contact

an authorized Polaris Quadricycle dealer or visit the

Polaris web site at www.polarisindustries.com.

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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

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SAFETY

Safety Labels and Locations

Discretionary

Warning

General

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

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SAFETY

Safety Labels and Locations

Age 16

Warning

“No Passenger”

Warning

Tire Pressure/Load

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

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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

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FEATURES AND CONTROLS

Switches

Headlight Switch

Engine

Stop Switch

Override

Switch

Main Key Switch

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.

WARNING! 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.

Engine Stop Switch

Move the stop switch either left or right to

the OFF position to stop the engine

quickly. The engine will not start or run

when the switch is off.

OFF

RUN

OFF

Both the main switch and the engine stop

switch will shut off all electrical power to

the vehicle, including lights.

Main Key Switch

Use the main key switch to start the engine. See page 34 for starting pro-

cedures.

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FEATURES AND CONTROLS

Switches

Headlight Switch

Use the headlight switch to turn the lights on and off and to change the

lights from high beam to low beam. The key must be in the ON position

and the engine stop switch must be in the RUN position to operate the

headlights.

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

Neutral Indicator

High Temperature Warning

(displays if engine overheats)

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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.

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.

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FEATURES AND CONTROLS

Brake Lever

Squeeze the brake lever toward

the handlebar to apply the front

and rear brakes. These brakes

are hydraulically activated disc

type brakes that are activated

by only one lever.

Always test brake lever travel

and master cylinder fluid level

before riding. When squeezed,

the lever should feel firm. Any

sponginess would indicate a possible fluid leak or low master cylinder

fluid level, which must be corrected before riding. Contact your dealer

for proper diagnosis and repairs.

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.

Inspect and maintain the brake fluid level as outlined in this manual. See

page 63.

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FEATURES AND CONTROLS

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 or fire. Always check to be sure the parking brake is disengaged before

operating.

The parking brake may relax if left on for a long period of time. Always

block the wheels to prevent rolling. Always block the wheels on the

downhill side of the vehicle if leaving it parked on a hill. Another option

is to park the vehicle in a sidehill position. Never depend on the parking

brake alone if the vehicle is parked on a hill. Always block the wheels to

prevent rolling.

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FEATURES AND CONTROLS

Auxiliary Foot Brake

Aggressively applying the auxiliary rear brake when backing down a hill may

cause rear tipover, which could result in serious injury or death. Never back

down a hill.

Use caution when applying the auxiliary brake. Do not aggressively apply the

auxiliary brake when going forward. The rear wheels may skid and slide

sideways, causing loss of control, which may result in serious injury or death.

The auxiliary brake serves as a

backup to the main brake sys-

tem if the main system

becomes inoperative.

The auxiliary foot brake is

located on the inside of the

right footrest. Operate this

brake with your right foot.

If the rear wheels slide while

using the auxiliary brake,

reduce brake pedal pressure to

brake the rear wheels without

skidding.

Auxiliary

Foot Brake

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FEATURES AND CONTROLS

Choke

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

procedure on page 34 for correct choke and throttle settings during start-

ing.

Fuel Tank Cap

Fuel

Tank

Cap

Always refuel with the engine

stopped, and outdoors or in a

well ventilated area. Refuel on

a level surface.

Remove the fuel tank cap to

add fuel to the fuel tank. Use

either leaded or unleaded gaso-

line with a minimum pump

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

octane. Do not use E-85 fuel.

Fuel

Valve

Fuel Valve

The fuel valve is located on

the left side of the vehicle,

below the fender.

ON: For normal operation.

OFF: For vehicle storage

and when transporting.

OFF

RES

RES: Turn the valve to the reserve setting if the main fuel supply is

exhausted. Refuel as soon as possible. Return the valve to the ON posi-

tion after refueling.

Reserve fuel range is about 7-10 miles (11-16 km).

Fuel Filter

The in-line fuel filter should be replaced by your dealer after every 100

hours of operation or annually. Do not attempt to clean the fuel filter.

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FEATURES AND CONTROLS

Transmission Gear Selector

The transmission gear selector is located

on the right side of the vehicle.

F: Forward Gear

N: Neutral

Gear

Selector

R: Reverse

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.

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OPERATION

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. Read and

understand all safety warnings outlined in the safety section of this owner’s

manual.

Break-In Period

The break-in period for your new Polaris 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 is as important as following the proce-

dures 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.

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

hours of use.

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OPERATION

Break-In Period

Engine and Drivetrain Break-in

1. Fill the fuel tank with gasoline. See page 28. Always exercise

extreme caution whenever handling gasoline.

2. Check the oil level. See page 56. Add oil as needed to maintain the

level in the proper range.

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

iarize yourself with vehicle operation and handling.

4. 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 33.

6. Pull only light loads (if equipped with a hitch).

7. Change both the oil and the filter at 20 hours or one month, which-

ever comes first.

PVT Break-in (Clutches/Belt)

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

and better performance. Break in the clutches and belt by operating at

slower speeds during the break-in period as recommended. Pull only

light loads. Avoid aggressive acceleration and high speed operation dur-

ing the break-in period.

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OPERATION

Safe Operation Practices

1. Complete the recommended safety training before operating this

vehicle. See page 7.

2. Do not allow anyone under 16 years of age to operate this vehicle.

Do not allow anyone with cognitive or physical disabilities to oper-

ate this vehicle.

3. Never carry a passenger on this vehicle.

4. Engine exhaust fumes are poisonous. Never start the engine or let it

run in an enclosed area.

5. Avoid sudden turns or swift movement of the handlebars when

operating on pavement.

6. Use caution and drive at reduced speeds in conditions of reduced

visibility such as fog, rain and darkness. Clean headlights fre-

quently and replace burned out headlamps promptly.

7. Drive in a manner appropriate for your skills and operating condi-

tions. Never operate at excessive speeds. Never attempt wheelies,

jumps, or other stunts. Never remove your hands from the handle-

bars while operating, and always keep both feet on the footrests.

8. Never consume alcohol or drugs before or while operating this vehi-

cle.

9. Always use the size and type of tires specified for your vehicle.

Always maintain proper tire pressure.

10. Never operate a damaged Quadricycle. After any overturn or acci-

dent, have a qualified service dealer inspect the entire machine for

possible damage.

11. Never operate the vehicle on a frozen body of water.

12. Familiarize yourself with all laws and regulations concerning the

operation of this vehicle in your area.

13. Do not touch hot exhaust system components. Always keep com-

bustible materials away from the exhaust system.

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

prevent unauthorized use.

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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

Brake system/lever travel

Ensure proper operation

Brake fluid

Ensure proper level

Auxiliary Foot brake

Front suspension

Rear suspension

Steering

Ensure proper operation

Inspect, lubricate if necessary

Ensure free operation

Tires

Inspect condition and pressure

Inspect, ensure fastener tightness

Wheels/fasteners

Frame nuts, bolts, fasteners Inspect, ensure tightness

Fuel and oil

Ensure proper levels

Coolant level

Coolant hoses

Throttle

Ensure proper level

Inspect for leaks

Ensure proper operation

Indicator lights/switches

Engine stop switch

Drive chain

Ensure operation

Ensure proper operation

Check condition/slack, lubricate as

needed

Air filter, pre-filter

Air box sediment tube

Headlamp

Inspect, clean

Drain deposits whenever visible

Check operation, apply Polaris dielec-

tric grease when lamp is replaced

Brake light/tail lamp

Riding gear

Check operation, apply Polaris dielec-

tric grease when lamp is replaced

Wear approved helmet, goggles, and

protective clothing

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OPERATION

Starting the Engine

1. Position the vehicle on a level surface outdoors or in a well-venti-

lated area.

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. Move the engine stop switch to RUN.

8. Do not press the throttle while starting the engine.

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OPERATION

Starting the Engine

9. Turn the ignition key past the ON position to engage the starter.

Activate the starter for a maximum of five seconds, releasing the

key when the engine starts.

NOTICE: Operating the vehicle immediately after starting could cause engine

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

operating the vehicle.

10. If the engine does not start, return the key to the OFF position and

wait five seconds before attempting to start again. Activate the

starter for another five seconds if necessary. Repeat this procedure

until the engine starts.

Tip: If a warm engine has cooled to a point where it does not readily start, inter-

mittent 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.

11. 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.

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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. Squeeze the brake lever.

4. Start the engine and allow it to warm up.

5. Shift the transmission into gear.

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

7. Release the brake lever.

8. Slowly squeeze the throttle lever toward the handlebar to begin

driving. Squeeze the throttle lever further to increase speed.

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

brakes on level surfaces.

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OPERATION

Turning the Vehicle

To turn, steer in the direction of the turn, leaning your upper body to the

inside of the turn while supporting your weight on the outer footrest.

The same leaning technique should be used for turning in reverse.

Practice making turns at slow speeds before attempting to turn at faster

speeds.

Turning improperly can result in vehicle overturn. Never turn abruptly or at sharp

angles. Never turn at high speeds.

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

quick, sharp turns, which can cause skids.

4. Never apply the brakes during a skid. Correct a skid by turning the

handlebars in the direction of the skid and shifting your body

weight forward.

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OPERATION

Driving Uphill

Braking and handling are greatly affected when operating in hilly ter-

rain. Improper procedure could cause loss of control or overturn. When-

ever traveling uphill, follow these precautions:

1. Drive straight uphill.

2. Avoid steep hills (25°

maximum).

3. Always check the ter-

rain carefully before

ascending any hill.

4. Avoid hills with exces-

sively slippery or loose

surfaces.

5. Keep both feet on the

footrests.

25° Maximum

6. Shift body weight

uphill.

7. Drive at a steady rate of speed to avoid stalling.

8. Never open the throttle suddenly or make sudden gear changes.

9. Never go over the top of a hill at high speed.

10. Be alert. Be prepared to take emergency action. This may include

dismounting quickly.

If all forward speed is lost:

Keep your weight uphill.

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

auxiliary brake as well, then lock the parking brake.

If the vehicle begins rolling downhill, never apply engine power. Never

apply the rear brakes while rolling backwards.

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

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

Dismount on the uphill side, or to either side if the vehicle is pointed

straight uphill. Turn the vehicle around and remount, following the pro-

cedure described on page 42.

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OPERATION

Driving on a Sidehill (Sidehilling)

Driving on a sidehill is not recommended. Improper procedure could

cause loss of control or overturn. Avoid crossing the side of any hill

unless absolutely necessary.

If crossing a sidehill is unavoidable, follow these precautions:

1. Slow down.

2. Avoid hills with excessively slippery or loose surfaces.

3. Avoid crossing the side of a steep hill.

4. Shift body weight uphill.

5. Keep your feet on the footrests.

6. If the vehicle begins to tip, quickly turn the front wheel downhill, if

possible, or dismount on the uphill side immediately!

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OPERATION

Driving Downhill

25° Maximum

When driving downhill, follow these precautions:

1. Avoid steep hills (25° maximum).

2. Avoid hills with excessively slippery or loose surfaces.

3. Shift body weight uphill.

4. Drive straight downhill.

5. Slow down. Never go down a hill at high speed.

6. Avoid going down a hill at an angle, which can cause the vehicle to

pitch sharply to one side.

7. Squeeze the brake lever gradually. Applying the brakes too firmly

may cause the rear wheels to lock, which could result in loss of con-

trol.

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OPERATION

Turning Around on a Hill (K-Turn)

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

Use the K-turn to turn around.

2.4 m

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

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

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

cle is pointing straight uphill.

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

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

slowly allow the vehicle to roll around to your right until it's point-

ing across the hill or slightly downward.

6. Lock the parking brake. Remount the vehicle from the uphill side,

keeping body weight uphill.

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

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

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

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OPERATION

Driving Through Water

Your Polaris vehicle can operate through water with a maximum recom-

mended depth equal to the bottom of the footrests. Follow these proce-

dures 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.

4. After leaving water,

test the brakes. Apply

them lightly several

times while driving

Maximum Depth

slowly. The friction

will help dry out the

pads.

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 50. 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 84,

then see your dealer for service at the first opportunity.

If it’s 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.

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OPERATION

Driving Over Obstacles

Follow these precautions when operating over obstacles:

1. Always check for obstacles before operating in a new area.

2. Be alert. Watch the terrain. Use extra caution

3. Never operate over large obstacles.

4. Avoid hazards such as logs, rocks and low branches.

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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.

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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.

CARGO WEIGHT DISTRIBUTION should be 1/3 on the front rack and 2/3 on

the rear rack. When operating over rough or hilly terrain, reduce speed and

cargo to maintain stable driving conditions. Carrying loads on only one rack

increases the possibility of vehicle overturn.

CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE. Carrying loads high

on the racks raises the center of gravity of the vehicle and creates a less stable

operating condition.

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.

DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the

front rack.

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.

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OPERATION

Hauling Cargo

Load Distribution

Accessory racks and hitches

are available from your

Polaris dealer. Read and

2/3

understand the load distribu-

tion warnings listed on the

vehicle warning labels. Never

exceed the specified weights.

1/3

Cargo weight should be

evenly distributed (1/3 on the

front rack and 2/3 on the rear

rack) and mounted as low as

possible. When operating

over rough or hilly terrain,

reduce speed and cargo

weight to maintain stable

driving conditions. Do not obstruct the headlight beam with cargo.

Towing Loads

Towing is approved OFF-ROAD ONLY. Operating a Quadricycle/trailer

combination on public roads is prohibited. 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 from

the vehicle 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.

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OPERATION

Parking on an Incline

Avoid parking on an incline. If it's unavoidable, follow these precau-

tions:

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.

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EMISSION CONTROL SYSTEMS

Noise Emission Control System

Do not modify the engine, intake or exhaust components, as doing so

may affect compliance with governmental noise level requirements.

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.

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MAINTENANCE

Periodic Maintenance Chart

Careful periodic maintenance will help keep your vehicle in the safest,

most reliable condition. Inspection, adjustment and lubrication of

important components are explained in the periodic maintenance chart.

Inspect, clean, lubricate, adjust and replace parts as necessary. When

inspection reveals the need for replacement parts, use genuine Polaris

parts available from your Polaris dealer.

Record maintenance and service in the Maintenance Log beginning on

page 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.

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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

Perform these operations more often for vehicles subjected to

severe use.

Emission-related service (Failure to conduct this maintenance will

not void the emissions warranty but may affect emissions.)

Have an authorized Polaris dealer perform these services.

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MAINTENANCE

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

Item

Maintenance Interval

Remarks

(whichever comes first)

Hours Calendar Kilometers

Steering

Pre-Ride

Daily

Make adjustments as need

ed. See Pre-Ride Checklist

on page 33.

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

Inspect; clean often; replace

as needed

X Air box sediment

Daily

Drain deposits when visible

tube

Coolant

Check level daily; change

coolant every 2 years

Headlamp/tail

lamp

Daily

Check operation; apply

dielectric grease if replacing

X Air filter,

E main element

Weekly

Monthly

Inspect; replace as needed

X Brake pad wear

100 (160) Inspect periodically

Battery

Monthly

200 (320) Check terminals; clean; test

250 (400) Inspect level; change yearly

X Front gearcase oil

(if equipped)

X Transmission oil

Monthly

250 (400) Inspect level; change yearly

250 (400) Inspect; clean if needed

X Engine breather

E filter (if equipped)

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.

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MAINTENANCE

Periodic Maintenance Chart

Item

Maintenance Interval

Remarks

(whichever comes first)

Hours Calendar

Miles

(Km)

X Engine oil change

1 M

3 M

6 M

250 (400) Perform a break-in oil change

E (break-in)

X General

500 (800) Lubricate all fittings, pivots,

cables, etc.

lubrication

Carburetor float

bowl

500 (800) Drain bowl periodically and

prior to storage

Throttle Cable/

ETC Switch

500 (800) Inspect; adjust; lubricate;

replace if necessary

Choke cable

6 M

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

1000 (1600) Inspect coolant strength

seasonally; pressure test

system yearly

X Engine oil change

100

6 M

1000 (1600) Perform a break-in oil change

at 20 hours

X Oil filter change

1000 (1600) Replace with oil change

X Oil tank vent hose

100

12 M

1000 (1600) Inspect routing, condition

1000 (1600) Inspect; adjust

Valve clearance

Fuel system/filter

100

12 M

1000 (1600) Check for leaks at tank cap,

lines, fuel valve, filter, pump,

carburetor; replace lines

every two years

X Radiator

100

12 M

1000 (1600) Inspect; clean external

surfaces

X Cooling hoses

1000 (1600) Inspect for leaks

(if applicable)

X Engine mounts

1000 (1600) Inspect

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MAINTENANCE

Periodic Maintenance Chart

Item

Maintenance Interval

Remarks

(whichever comes first)

Hours Calendar

Miles

(Km)

Exhaust muffler/

pipe

100

12 M

1000 (1600) Inspect

Spark plug

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.

Clutches (drive

100

12 M

1000 (1600) Inspect; clean; replace worn

parts

and driven)

Front wheel

bearings

1000 (1600) Inspect; replace as needed

Brake fluid

200

300

24 M

36 M

2000 (3200) Change every two years

3000 (4800) Clean out

Spark arrestor

E Idle speed

Adjust as needed

Toe adjustment

Inspect periodically; adjust

when parts are replaced

Headlight aim

Adjust as needed

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.

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MAINTENANCE

Lubrication Guide

Check and lubricate all components at the intervals outlined in the Peri-

odic Maintenance Chart beginning on page 50. Items not listed in the

chart should be lubricated at the General Lubrication interval.

Item

Lube

Method

Engine Oil

PS-4 PLUS Performance See page 56.

Synthetic 2W-50

Brake Fluid

DOT 4 Only

See page 63.

Drive Chain(s)

O-ring chain lube or SAE Lubricate.

80/90

Transmission Oil

Polaris AGL Synthetic

Gearcase Lube

See page 60.

Swing Arm Bushings

Axle Housing

XPremium All Season

Grease

Locate fittings on swing arm and

grease with grease gun

Tie Rod Ends

XPremium All Season

Grease

Lift boot, clean away dirt and

grease, apply fresh grease by hand

and reassemble. Perform when

suspension action becomes stiff, or

after washing.

Axle

Housing

Tie Rod

Ends

Swing Arm

Bushings

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MAINTENANCE

Engine Oil

Oil Recommendations

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.

NOTICE: 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.

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MAINTENANCE

Oil and Filter Change

Always change the oil and filter at the intervals outlined in the Periodic

Maintenance Chart beginning on page 50. 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.

CAUTION! 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 56.

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.

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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 56. 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 59. 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.

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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.

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MAINTENANCE

Transmission Oil

Always check and change the transmission oil at the intervals outlined

in the Periodic Maintenance Chart beginning on page 50. Maintain the

oil level within the SAFE operating range on the dipstick.

Transmission Oil Recommendations

Gearcase

Lubricant

Capacity

Drain Plug Torque

Transmission

Premium AGL Synthetic

Gearcase Lubricant

11.3 oz.

(334 ml)

14 ft. lbs.

(19 Nm)

Oil Check

1. Position the vehicle on a level surface.

2. The transmission oil dipstick is located on the right side of the vehi-

cle. Remove the dipstick and wipe it clean.

3. Reinstall the dipstick

completely, then remove

it and check the level.

4. Add the recommended

Safe

Range

lubricant to bring the level

into the safe operating

range.

5. Reinstall the dipstick.

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MAINTENANCE

Transmission Oil

Oil Change

1. Position the vehicle on a level

surface.

Adjuster

Bolt

Jam

Nut

2. Place a drain pan beneath the

transmission oil drain plug area.

3. Loosen the jam nut.

4. Turn the adjuster bolt in to allow

the removal of the drain plug.

5. Remove the drain plug and wipe

the magnetic end clean to

remove accumulated metallic

filings.

6. After the oil has drained com-

pletely, install a new sealing

washer and reinstall the drain

plug. Torque to specification.

Drain Plug

7. Turn the adjuster bolt out until it

touches the frame, and then turn

an additional 1/2 turn.

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

9. Remove the dipstick. Add the recommended lubricant until the oil

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

10. Reinstall the dipstick

11. Check for leaks. Discard used oil properly.

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MAINTENANCE

Brakes

Brake Fluid

An over-full master cylinder may cause brake drag or brake lock-up, which could

result in an accident. Maintain brake fluid at the recommended level. Do not

overfill.

Once open, a bottle of brake fluid absorbs moisture from the air, which causes

the boiling temperature of the brake fluid to drop. This can lead to early brake

fade and the possibility of accident. Do not store opened brake fluid. Properly

discard any unused portion.

Always maintain brake fluid at the recommended level. Do not overfill.

If the fluid level is low add DOT 4 brake fluid only. See page 104 for the

part numbers of Polaris products.

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.

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MAINTENANCE

Brakes

Brake Fluid (Hand Brake)

Check the brake fluid level in the

master cylinder before each use of

the vehicle. The master cylinder is

located on the left handlebar.

Master Cylinder

Maintain the fluid level 1/4" (6

mm) below the top edge of the

master cylinder. Do not overfill.

1. Position the vehicle on a level

surface. Make sure the han-

dlebars are straight.

Indicator

Window

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.

Brake Fluid (Auxiliary Foot Brake)

Check the brake fluid level fre-

quently for the auxiliary brake sys-

Full

tem. The reservoir is located under

the seat or near the foot brake. Main-

tain the fluid level between the maxi-

mum and minimum marks.

Add

The brakes should feel firm when

they're applied. Spongy or weak

brakes may indicate a fluid leak or

low fluid level. A low fluid level may also mean that brake pads are

worn and need to be replaced. Do not operate the vehicle with spongy or

weak brakes. See your dealer for service.

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MAINTENANCE

Brakes

Brake Check

Perform the following checks to keep

the brake systems in good operating

condition. Check more often if brakes

are used heavily during normal opera-

tion.

1. Always keep foot brake fluid at an

adequate level. Check the foot brake

system regularly for fluid leaks.

2. Check the brakes for excessive

travel or spongy feel.

3. Check the brake pads for wear, dam-

age or looseness. Replace pads

when they are worn to 1 mm.

1 mm

4. Check the security and surface condition of the brake discs.

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MAINTENANCE

Toe Alignment

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

The recommended toe alignment is 3-6 mm toe out.

WARNING! Severe injury or death can result from improper toe alignment and

adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments

should be performed by an authorized Polaris dealer.

1. Position the vehicle on a level surface.

2. 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 25 cm from

the floor, or as close to the

hub/axle center line as pos-

sible. Make sure both marks

are the same distance from

the floor.

4. Measure the distance

between the marks and

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.

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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 preload and

shock compression damping may be

adjusted to suit different riding condi-

tions and operator weight.

Spring Preload

1. Raise and safely support the rear of

Adjusting

the vehicle off the ground to allow

Ring

the suspension to fully extend.

2. Loosen the jam nut and back it

away from the adjusting ring.

3. Turn the adjusting ring counter-

clockwise (1) to increase preload.

Turn the ring clockwise (2) to

decrease preload.

4. Tighten the jam nut firmly against

the adjuster ring.

Jam

Nut

Compression Damping

Clicker

Use a flat-blade screwdriver to make

damping adjustments. The factory setting

is at 10 clicks from fully closed.

The compression damping clicker is

located on the end of the shock reservoir.

1. Turn the clicker clockwise (1) to

increase compression damping.

2. Turn the clicker counter-clockwise

(2) to decrease compression damp-

ing.

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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 1.6-3 mm of

freeplay exists at the 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

Sleeve

Lock Nut

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MAINTENANCE

Handlebars

WARNING! Improper adjustment of the handlebars or incorrect torquing of the

adjuster block tightening bolts can cause limited steering or loosening of the

handlebars, resulting in loss of control and serious injury or death. Follow the

adjustment procedures exactly, or see your Polaris dealer for service.

The handlebars can be adjusted for rider preference.

1. Remove the handlebar cover.

Handlebar Bolts

2. Loosen (do not remove) the four

handlebar clamp 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.

Tip: A gap of up to 3 mm should remain at the rear bolts.

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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 engine damage. See your

Polaris dealer for more information about jetting.

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. Position the vehicle on a level sur-

face. Place the transmission in gear.

Lock the parking brake.

2. Start the engine. Allow it to idle for

approximately five minutes. Stop

the engine.

3. Turn the carburetor idle screw in

Idle

Adjuster

(clockwise) to raise RPM. Turn the

screw out (counterclockwise) to

lower RPM.

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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 104 for the

part numbers of Polaris products.

NOTICE: Washing the drive chain with a high pressure washer or gasoline can

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

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

the drive chain.

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MAINTENANCE

Drive Chain

Rear Drive Chain Slack

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.

NOTICE: 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.

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.

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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.

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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 104 for the part

numbers 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

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MAINTENANCE

Cooling System

Radiator Coolant

To ensure that the coolant maintains its ability to protect the engine,

Polaris recommends that you drain the system completely every two

years and add a fresh mixture of antifreeze and water.

Replace the coolant any time the cooling system has been drained for

maintenance or repair. If the recovery bottle has run dry, check the level

in the radiator. Add coolant as needed.

CAUTION! Escaping steam can cause burns. 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 the radiator pressure

cap.

2. Remove the pressure cap.

3. If coolant is low, use a fun-

nel and slowly add coolant

through the radiator filler

neck.

4. Reinstall the pressure cap.

Radiator Cap

Use of a non-standard pres-

sure 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.

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MAINTENANCE

Lights

Poor lighting can result in reduced visibility when driving. Headlight

and taillight lenses become dirty during normal operation. Clean lights

frequently and replace burned out lamps promptly. Always make sure

lights are adjusted properly for best visibility.

Headlamp Replacement

When servicing a halogen lamp, don't touch the lamp with bare fingers.

Oil from your skin leaves a residue, causing a hot spot that will shorten

the life of the lamp.

1. Remove the wire harness connector from the back of the headlight.

CAUTION! Hot components can cause burns to skin. Allow lamps to cool

before servicing.

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.

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MAINTENANCE

Lights

Taillight/Brakelight Lamp Replacement

1. Remove the taillight lens cover

mounting screws. Remove the

lens cover and gasket and set

aside for reassembly.

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 operation.

5. Reinstall the gasket and lens cover.

Indicator Lamp Replacement

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

indicator panel.

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

1/4 turn counterclockwise.

3. Using a needle-nose 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.

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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 resulting in serious injury or death. Always follow all tire maintenance

procedures as outlined in this manual and on the labels on the vehicle. Always

use original equipment size and type when replacing tires.

Refer to the specifications section beginning on page 102 for recom-

mended tire type, size and pressure.

Wheel and Hub Tightening

Wheel hub and bearing tightness and spindle nut retention are critical

items. These services must be performed by an authorized dealer.

Tire Tread Depth

3 mm

Always replace tires

when tread depth is

worn to 3 mm or less.

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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.

3. Safely place jackstands under the

vehicle.

4. Remove the wheel nuts. 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 79).

WARNING! 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.

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MAINTENANCE

Tires

Wheel Nut Torque Specifications

Rear

50 ft. lbs.

(68 Nm)

Front

27 ft. lbs.

(37 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)

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MAINTENANCE

Air Filter

1. Position the vehicle on a level surface. Place the transmission in

gear. Lock the parking brake.

2. Remove the seat.

Pre-Filter

3. Release the air box cover

clips, and remove the air

box cover.

Main Filter

4. Loosen the clamp and

remove the filter.

5. Remove the pre-filter

from the main filter.

6. Wash the pre-filter in

soapy water, then rinse

and let dry.

7. Reinstall the pre-filter

over the main filter.

Replace the main filter if

needed.

8. Reinstall the air filter into the air box. Tighten the clamp, but do not

over-tighten as filter damage could occur.

9. Reinstall the air box cover and the seat.

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MAINTENANCE

Breather Filter

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.

Breather Filter

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.

NOTICE: Operation of your vehicle without a breather filter can cause engine

damage. Always reinstall the breather filter after removing it for

service.

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MAINTENANCE

Spark Plugs

Spark Plug Recommendations

Refer to the specifications section beginning on page 102 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 83.

A hot exhaust system and engine can cause burns. Wear protective gloves

when removing a spark plug for inspection.

1. Remove the spark plug cap.

2. Using the special wrench pro-

vided in the tool pouch, rotate

the spark plug counterclock-

wise 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.

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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.

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MAINTENANCE

Vehicle Immersion

If the vehicle stops while fully submerged, major engine damage can

result if the machine is not thoroughly inspected. Take the vehicle to

your dealer before starting the engine.

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 88 for drying.

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MAINTENANCE

Spark Arrestor

WARNING

Failure to heed the following warnings while servicing the spark arrestor could

result in serious injury or death. 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. Place the transmission in neutral. Lock the parking brake. 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.

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MAINTENANCE

PVT System

WARNING

Failure to comply with the instructions in this warning can result in severe injury

or death.

Do not modify any component of the PVT system. Doing so may reduce its

strength so that a failure may occur at a high speed. The PVT system has been

precision balanced. Any modification will cause the system to be out of balance,

creating vibration and additional loads on components.

The PVT system rotates at high speeds, creating large amounts of force on

clutch components. Extensive engineering and testing has been conducted to

ensure the safety of this product. However, as the owner, you have the following

responsibilities to make sure this system remains safe:

• Always follow all recommended maintenance procedures. See your dealer as

outlined in the owner's manual.

• This PVT system is intended for use on Polaris products only. Do not install it

in any other product.

• Always make sure the PVT housing is securely in place during operation.

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MAINTENANCE

PVT System

The basic operation of the Polaris PVT system is dependent on engine

speed and vehicle torque requirements. As engine speed increases, the

force exerted on the movable drive sheave by the flyweights also

increases. This, in turn, increases the amount of pinch applied to the

drive belt. Similarly, if the engine speed decreases, the amount of 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.

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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.

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MAINTENANCE

Battery

WARNING

Improperly connecting or disconnecting battery cables can result in an explosion

and cause serious injury or death. When removing the battery, always

disconnect the negative (black) cable first. When reinstalling the battery, always

connect the negative (black) cable last.

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.

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MAINTENANCE

Battery

Battery Removal

1. Place the transmission in gear.

2. Lock the parking brake.

3. Disconnect the battery hold-down strap.

4. Remove the battery cover.

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

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

7. Disconnect the red (positive) battery cable last.

8. 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.

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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 93 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.

WARNING! Battery gases could accumulate in an improperly installed vent tube

and cause an explosion, resulting in serious injury or death. Always ensure that

the vent tube is free of obstructions and is securely installed as recommended.

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

or petroleum jelly.

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

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

7. Install the battery cover.

8. Secure the battery hold-down strap.

9. Verify that cables are properly routed. Cables should be safely

tucked away at the front and rear of the battery.

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MAINTENANCE

Battery

Battery Storage

Whenever the vehicle is not used for a period of three months or more,

remove the battery from the vehicle, ensure that it's fully charged, and

store it out of the sun in a cool, dry place. Check battery voltage each

month during storage and recharge as needed to maintain a full charge.

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 104 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.

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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 90.

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 91. 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.

WARNING! 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.

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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

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

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MAINTENANCE

Cleaning and Storage

Washing the Vehicle

Keeping the vehicle clean will extend the life of 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.

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MAINTENANCE

Cleaning and Storage

Washing the Vehicle

If a high pressure water system is used for cleaning (not recommended),

exercise extreme caution. The water may damage components. Avoid

directing the water stream at the following 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.

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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.

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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 95.

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. Stop the engine.

5. Turn the fuel valve off.

6. Drain the carburetor bowl.

Oil and Filter

Change the oil and filter. See page 57.

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.

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MAINTENANCE

Cleaning and Storage

Storage Tips

Fluid Levels

Inspect the fluid levels. Change fluids as recommended in the Periodic

Maintenance Chart beginning on page 50.

• 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 98.

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.

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MAINTENANCE

Cleaning and Storage

Storage Tips

Inspect and Lubricate

Inspect all cables and lubricate all areas of the vehicle as recommended

in the Periodic Maintenance Chart beginning on page 50.

Battery Storage

See page 92-94 for storage and charging procedures.

Storage Area/Covers

1. Make sure tire pressure is at specification.

2. Using suitable supports under the frame, raise the vehicle slightly so

that the tires are not touching the ground.

3. Be sure the storage area is well ventilated.

4. Cover the machine with an appropriate cover. Do not use plastic or

coated materials, as they do not allow proper ventilation to prevent

condensation, corrosion and oxidation.

100

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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

bumper, racks or handle-

bars.

101

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SPECIFICATIONS

Scrambler 500 2X4

Maximum Weight Capacity

305 lbs. (138 kg) (includes weight of opera-

tor, cargo and accessories)

Dry Weight

530 lbs. (240 kg)

Fuel Capacity

3.5 gal. (13.2 l)

Engine Oil Capacity

Transmission Oil

2 qts. (1.9 l)

11.3 oz. (334 ml)

Coolant

2.25 qts. (2.13 l)

Front Rack Capacity (Accessory)

Rear Rack Capacity (Accessory)

Hitch Tongue Weight Capacity

30 lbs. (13.6 kg) (Maximum)

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)

46 in. (117 cm)

47 in. (114 cm)

48 in. (122 cm)

5.5 in. (14 cm)

75 in. (190.5 cm) unloaded

4 Cycle, Single Cylinder

Dry sump

Overall Height

Wheelbase

Ground Clearance

Minimum Turning Radius

Engine Model Number/Type

Lubrication

Engine Cooling

Displacement

Liquid

499 cc

Bore x Stroke

92 x 75

Alternator Output

Compression Ratio

Carburetor

250w @5000 rpm

10.2:1

BST 40

Pilot Jet

Main Jet

155

Needle Jet

Y-0M (896)

Jet Needle

6H25-94-3

Pilot Air Jet

160

Pilot Screw

2.0 turns

Ignition System

Ignition Timing

Spark Plug / Gap

CDI

30° +/- 2° @ 5000 RPM

BKR6E / .036 in. (.9 mm)

* Based on EU Directive 76/432/EC

102

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SPECIFICATIONS

Scrambler 500 2X4

Driving System Type

Shift Type

PVT (Polaris Variable Transmission)

Side Lever (F/N/R)

Gear Reduction, Reverse

Gear Reduction, Forward

Drive Ratio, Final

Drive Chain

3.05:1

2.68:1

12/36 76P

520 O-Ring

Tires/Pressure, Front

Tires/Pressure, Rear

Front Suspension

Rear Suspension

Shock Adjustment

Brakes, Front

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

22 x 12-10 (3 psi/20.7 kPa)

MacPherson strut with 8.2" (21 cm) travel

Progressive rate with 10.5" (26.7 cm) travel

Threaded Adjuster

Fixed disc, hydraulic floating caliper

Hydraulic lock, all wheel

2 Dual Beam 30w/30w

12V 14AH

Brakes, Rear

Brake, Auxiliary

Brake, Parking

Headlight

Battery

Indicators

High Beam/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)

10WH

5630710

Blue/Green

7041157

Silver

7041499

40°

5131446

1+1

1800 & above

(6000 & above)

10RH

5630709

Blue/Green

7041157

Silver

7041499

40°

5131446

1+1

103

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POLARIS PRODUCTS

Part #

Description

Engine Lubricant

2870791 Fogging Oil (12 oz. Aerosol)

2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt./.95 l)

2876245 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal./3.8 l)

Gearcase / Transmission Lubricants

2873602 Premium AGL Synthetic Gearcase Lubricant (qt./.95 l)

2873603 Premium AGL Synthetic Gearcase Lube (gal./3.8 l)

2871653 Premium ATV Angle Drive Fluid (8 oz./237 ml)

2872276 Premium ATV Angle Drive Fluid (2.5 gal./9.5 l)

2870465 Pump for Gallon Jug

2871654 Premium Demand Drive Hub Fluid (8 oz./237 ml)

2872277 Premium Demand Drive Hub Fluid (2.5 gal./9.5 l)

Coolant

2871323 60/40 Coolant (gal./3.8 l)

2871534 60/40 Coolant (qt./.95 l)

Grease / Specialized Lubricants

2871312 Grease Gun Kit, Premium All Season (3 oz./89 ml)

2871322 Premium All Season Grease (3 oz./89 ml cartridge)

2871423 Premium All Season Grease (14 oz./.4 l cartridge)

2871460 Starter Drive Grease (2 oz./59 ml)

2871515 Premium U-Joint Lube (3 oz./89 ml)

2871551 Premium U-Joint Lube (14 oz./.4 l)

Dielectric Grease (Nyogel^TM

)

2871329

2872073 Chain Lube, Aerosol (6.25 oz./185 ml)

2872348 Chain Lube, Aerosol (16 oz./.47 l)

Additives / Miscellaneous

2871326 Carbon Clean Plus (12 oz./355 ml)

2870652 Fuel Stabilizer (16 oz./.47 l)

2872189 DOT4 Brake Fluid (12 oz./355 ml)

Loctite^TM565 Thread Sealant

Polaris Battery Tender^TMCharger

2871956

2859044

104

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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 42).

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 88. 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 31.

105

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TROUBLESHOOTING

Engine Doesn't Turn Over

Possible Cause

Solution

Reset the breaker

Tripped circuit breaker

Low battery voltage

Recharge the battery to 12.8 VDC

Check all connections and tighten

Loose battery connections

Loose solenoid connections

Engine Turns Over, Fails to Start

Possible Cause

Solution

Out of fuel

Turn fuel valve to reserve, refuel

Inspect and clean or replace

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 on

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

Mechanical failure

See your dealer

106

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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 plug(s)

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

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

107

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TROUBLESHOOTING

Engine Stops or Loses Power

Possible Cause

Solution

Out of fuel

Turn fuel valve to reserve, refuel

Inspect and replace

Kinked or plugged fuel vent line

Water is present in fuel

Replace with new fuel

Overuse of choke

Inspect, clean and/or replace spark plugs

See your dealer

Fouled or defective spark plug(s)

Worn or defective spark plug wires

Incorrect spark plug gap or heat range

Loose ignition connections

Low battery voltage

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

Clean engine exterior; see your Polaris

dealer

108

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WARRANTY

LIMITED WARRANTY

Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a TWO YEAR

LIMITED WARRANTY on all components of the Polaris Quadricycle against defects in

material or workmanship. This warranty covers the parts and labor charges for repair or

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

on the date of purchase. This warranty is transferable to another consumer during the

warranty period through a Polaris dealer.

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. THE PURCHASER MUST COMPLETE A

QUADRICYCLE SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN

ORDER TO HAVE VALID WARRANTY ON THE QUADRICYCLE. No verification

of registration will be sent to the purchaser as the copy of the Warranty Registration

Form will be the warranty entitlement. If you have not signed the original registration

and received the "customer copy", please contact your dealer immediately. NO WAR-

RANTY COVERAGE WILL BE ALLOWED UNLESS YOUR QUADRICYCLE IS

REGISTERED WITH POLARIS.

Initial dealer preparation and set-up of your vehicle 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.

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 Quadricycle

that has been altered structurally, modified, neglected, improperly maintained, used for

racing, or used for purposes other than for which it was manufactured, or for any dam-

ages 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.

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

are not compatible with the Quadricycle. The exclusive remedy for breach of this war-

ranty shall be, at Polaris' exclusive option, repair or replacement of any defective materi-

als, or components or products. THE REMEDIES SET FORTH IN THIS WARRANTY

ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF

THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON

FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY

DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR-

RANTY 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

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WARRANTY

LIMITATIONS OF WARRANTIES AND REMEDIES

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 Quadricycle requires warranty service, you must take it to a Polaris dealer autho-

rized to repair Polaris Quadricycles. When requesting warranty service you must present

your copy of the Warranty Registration form to the dealer. (THE COST OF TRANS-

PORTATION 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 personnel at Polaris.

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

vary from state to state.

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

terms will remain in effect.

110

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MAINTENANCE LOG

DATE

MILES (KM)

OR HOURS

TECHNICIAN

SERVICE PERFORMED / COMMENTS

111

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MAINTENANCE LOG

DATE

MILES (KM)

OR HOURS

TECHNICIAN

SERVICE PERFORMED / COMMENTS

112

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INDEX

Air Filter . . . . . . . . . . . . . . . . . . . . . . 80

Driving Downhill . . . . . . . . . . . . . . . 41

Driving in Reverse . . . . . . . . . . . . . . 45

Driving on a Sidehill. . . . . . . . . . . . . 40

Driving on Slippery Surfaces . . . . . . 38

Driving Over Obstacles . . . . . . . . . . 44

Driving Procedures . . . . . . . . . . . . . . 36

Driving Properly . . . . . . . . . . . . . . . . 36

Driving Through Water . . . . . . . . . . 43

Driving Uphill. . . . . . . . . . . . . . . . . . 39

Battery . . . . . . . . . . . . . . . . . . . . 89-94

Charging (Conventional) . . . . . 93

Charging (Sealed) . . . . . . . . 93-94

Fluid (Conventional). . . . . . . . . 92

Installation . . . . . . . . . . . . . . . . 91

Removal . . . . . . . . . . . . . . . . . . 90

Storage . . . . . . . . . . . . . . . . . . . 92

Boots . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Brake, Parking Brake . . . . . . . . . . . . 26

Brake Check . . . . . . . . . . . . . . . . . . . 64

Brake Fluid . . . . . . . . . . . . . . . . . 62-63

Brake Fluid (Auxiliary Foot Brake) . 63

Brake Fluid (Hand Brake). . . . . . . . . 63

Brake Lever. . . . . . . . . . . . . . . . . . . . 25

Brake Maintenance . . . . . . . . . . . 62-64

Brake, Foot . . . . . . . . . . . . . . . . . . . . 27

Break-In Period. . . . . . . . . . . . . . 30-31

Breather Filter. . . . . . . . . . . . . . . . . . 81

Electromagnetic Interference . . . . . . 49

Engine Break-In . . . . . . . . . . . . . . . . 31

Engine Fogging. . . . . . . . . . . . . . . . . 99

Engine Idle RPM Adjustment. . . . . . 69

Engine Oil. . . . . . . . . . . . . . . . . . . . . 56

Equipment Modifications . . . . . . . . . . 7

Exhaust Emission Control System . . 49

Eye Protection. . . . . . . . . . . . . . . . . . . 9

Fluid, Brake . . . . . . . . . . . . . . . . . . . 62

Foot Brake, Auxiliary . . . . . . . . . . . . 27

Fuel Filter . . . . . . . . . . . . . . . . . . . . . 28

Fuel Safety . . . . . . . . . . . . . . . . . . . . 11

Fuel Tank Cap. . . . . . . . . . . . . . . . . . 28

Fuel Valve. . . . . . . . . . . . . . . . . . . . . 28

Carburetor . . . . . . . . . . . . . . . . . . . . . 69

Carburetor Adjustment . . . . . . . . . . . 69

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

Choke . . . . . . . . . . . . . . . . . . . . . . . . 28

Chrome Wheel Care . . . . . . . . . . . . . 97

Cleaning and Storage . . . . . . . . 95-100

Clothing . . . . . . . . . . . . . . . . . . . . . . . 9

Clutching Chart. . . . . . . . . . . . . . . . 103

Compression Damping, Rear . . . . . . 66

Coolant Bottle. . . . . . . . . . . . . . . . . . 73

Coolant, Radiator . . . . . . . . . . . . . . . 74

Cooling System. . . . . . . . . . . . . . 73-74

Corrosion Removal, Chrome . . . . . . 97

Gasoline Handling . . . . . . . . . . . . . . 11

Gear Selector . . . . . . . . . . . . . . . . . . 29

Gloves. . . . . . . . . . . . . . . . . . . . . . . . . 9

Handlebar Adjustment . . . . . . . . . . . 68

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

Headlamp Replacement . . . . . . . . . . 75

Headlight Switch . . . . . . . . . . . . . . . 23

Helmet. . . . . . . . . . . . . . . . . . . . . . . . . 8

Drive Belt Wear/Burn. . . . . . . . . . . 105

Drive Chain. . . . . . . . . . . . . . . . . 70-72

Drive Chain Lubrication . . . . . . . . . . 70

Drive Chain Slack. . . . . . . . . . . . 71-72

Drivetrain Break-In. . . . . . . . . . . . . . 31

113

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INDEX

Idle RPM Adjustment . . . . . . . . . . . 69

Immersion . . . . . . . . . . . . . . . . . . . . 84

Indicator Lights . . . . . . . . . . . . . . . . 23

Parking Brake . . . . . . . . . . . . . . . . . . 26

Parking on an Incline. . . . . . . . . . . . . 48

Periodic Maintenance Chart . . . . 50-54

Polaris Product List . . . . . . . . . . . . . 104

Polishing the Vehicle. . . . . . . . . . . . . 96

Pre-Ride Checklist. . . . . . . . . . . . . . . 33

PVT Break-In . . . . . . . . . . . . . . . . . . 31

PVT Drying . . . . . . . . . . . . . . . . . . . . 88

PVT System. . . . . . . . . . . . . . . . . 86-88

Jetting Chart. . . . . . . . . . . . . . . . . . 103

Key Switch. . . . . . . . . . . . . . . . . . . . 22

K-Turn . . . . . . . . . . . . . . . . . . . . . . . 42

Reverse Operation . . . . . . . . . . . . . . . 45

Riding Gear . . . . . . . . . . . . . . . . . . . 8-9

Lights . . . . . . . . . . . . . . . . . . . . . 75-76

Headlamp . . . . . . . . . . . . . . . . 75

Indicator Lamp . . . . . . . . . . . . 76

Taillight/Brakelight . . . . . . . . 76

Load Distribution. . . . . . . . . . . . . . . 47

Lubrication Guide . . . . . . . . . . . . . . 55

Safe Operation Practices . . . . . . . . . . 32

Safety Labels . . . . . . . . . . . . . . . 18-21

"No Passenger" Warning. . . . . . 20

Age 16 Warning. . . . . . . . . . . . . 21

Clutch Cover Warning. . . . . . . . 21

Discretionary Warning . . . . . . . 19

General Warning . . . . . . . . . . . . 18

Reverse Override Warning . . . . 21

Tire Pressure/Load Warning . . . 20

Safety Training . . . . . . . . . . . . . . . . . . 7

Severe Use. . . . . . . . . . . . . . . . . . . . . 50

Shifter . . . . . . . . . . . . . . . . . . . . . . . . 29

Sidehilling . . . . . . . . . . . . . . . . . . . . . 40

Signal Words . . . . . . . . . . . . . . . . . . . . 4

Spark Arrestor . . . . . . . . . . . . . . . . . . 85

Spark Plugs . . . . . . . . . . . . . . . . . 82-83

Spring Preload, Rear . . . . . . . . . . . . . 66

Starting the Engine . . . . . . . . . . . 34-35

Steering Assembly. . . . . . . . . . . . . . . 66

Storage. . . . . . . . . . . . . . . . . . . . 95-100

Suspension Adjustments, Rear . . . . . 66

Switches . . . . . . . . . . . . . . . . . . . 22-23

Engine Stop Switch . . . . . . . . . . 22

Headlight Switch . . . . . . . . . . . . 23

Main Key Switch. . . . . . . . . . . . 22

Maintenance Chart. . . . . . . . . . . . 50-54

Maintenance Chart Key. . . . . . . . . . 51

Modifications. . . . . . . . . . . . . . . . . . . 7

Noise Emission Control System . . . 49

Oil

Engine . . . . . . . . . . . . . . . . . . . 56

Transmission . . . . . . . . . . . . 60-61

Oil and Filter Change. . . . . . . . . . 57-59

Oil Level, Engine. . . . . . . . . . . . . . . 56

Oil Pump Priming . . . . . . . . . . . . . . 59

Oil Recommendations

Engine . . . . . . . . . . . . . . . . . . . 56

Transmission . . . . . . . . . . . . . . 60

Oil Specifications, Engine . . . . . . . . 56

Operator Safety . . . . . . . . . . . . . . 10-17

Override Switch. . . . . . . . . . . . . . . . 22

114

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INDEX

Throttle Cable Freeplay . . . . . . . . . . 67

Throttle Lever . . . . . . . . . . . . . . . . . . 24

Tires . . . . . . . . . . . . . . . . . . . . . . 77-79

Tread Depth . . . . . . . . . . . . . . . 77

Wheel and Hub Tightening. . . . 77

Wheel Installation. . . . . . . . . . . 78

Wheel Nut Torque . . . . . . . . . . 79

Wheel Removal. . . . . . . . . . . . . 78

Toe Alignment . . . . . . . . . . . . . . . . . 65

Towing Loads . . . . . . . . . . . . . . . . . . 47

Training. . . . . . . . . . . . . . . . . . . . . . . . 7

Transmission Oil. . . . . . . . . . . . . 60-61

Transporting the Vehicle . . . . . . . . 101

Turning Around on a Hill . . . . . . . . . 42

Turning the Vehicle . . . . . . . . . . . . . 37

Vehicle Identification Numbers . . . . . 6

Vehicle Immersion . . . . . . . . . . . . . . 84

Warning Symbols . . . . . . . . . . . . . . . . 4

Washing the Vehicle. . . . . . . . . . 95-96

Wheel and Hub Tightening. . . . . . . . 77

Wheel Installation. . . . . . . . . . . . . . . 78

Wheel Nut Torque Specifications. . . 79

Wheel Removal . . . . . . . . . . . . . . . . 78

115

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