Polaris Offroad Vehicle 500 HO User Manual

Pantone 426C  
Sportsman 500 HO  
Owner's Manual  
for Maintenance and Safety  
Read this manual carefully. It contains important safety information.  
This is an adult vehicle only.  
Operation is prohibited for those under 16 years of age.  
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WARNING  
The engine exhaust from this product contains chemicals  
known to the State of California to cause cancer, birth defects  
or other reproductive harm.  
A card containing important ATV safety information should be  
attached to the owner's manual on the next page. If you cannot  
locate this card, or if it has been removed, please call 1-800-  
342-3764 for assistance.  
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The text is printed on 100% recycled  
with 40% post-consumer waste (PCW).  
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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)  
®
RANGER utility vehicles  
®
• Victory Motorcycles  
We believe Polaris sets a standard of excellence for all utility and recre-  
ational vehicles manufactured in the world today. Many years of experi-  
ence have gone into the engineering, design, and development of your  
Polaris vehicle, making it the finest machine we’ve ever produced.  
For safe and enjoyable operation of your vehicle, be sure to follow the  
instructions and recommendations in this owner’s manual. Your manual  
contains instructions for minor maintenance, but information about  
major repairs is outlined in the Polaris Service Manual and should be  
®
performed only by a factory certified Master Service Dealer (MSD)  
technician.  
Your Polaris dealer knows your vehicle best and is interested in your  
total satisfaction. Be sure to return to your dealership for all of your ser-  
vice needs during, and after, the warranty period.  
We also take great pride in our complete line of apparel, parts and acces-  
sories, available through our online store at www.purepolaris.com. Have  
your accessories and clothing delivered right to your door!  
1
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POLARIS, THE WAY OUT and SPORTSMAN are registered trademarks of Polaris  
Industries Inc.  
Copyright 2009 Polaris Sales Inc. All information contained within this publication is  
based on the latest product information at the time of publication. Due to constant  
improvements in the design and quality of production components, some minor discrep-  
ancies may result between the actual vehicle and the information presented in this publi-  
cation. Depictions and/or procedures in this publication are intended for reference use  
only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse  
of the depictions and/or procedures contained within, whether whole or in part, is  
expressly prohibited.  
Printed in U.S.A.  
2010 Sportsman 500 HO Owner’s Manual  
P/N 9922247  
2
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TABLE OF CONTENTS  
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  
Features and Controls . . . . . . . . . . . . . . . . . . . 24  
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41  
Emission Control Systems . . . . . . . . . . . . . . . 61  
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 62  
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 113  
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 117  
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 118  
Declaration of Conformity. . . . . . . . . . . . . . . 120  
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121  
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 129  
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131  
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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. A Polaris ATV is not a toy and can be  
hazardous to operate. This vehicle handles differently than other vehicles, such  
as motorcycles and cars. A collision or rollover can occur quickly, even during  
routine maneuvers like turning, or driving on hills or over obstacles, if you fail to  
take proper precautions.  
• Read this owner’s manual. Understand all safety warnings, precautions and  
operating procedures before operating a Polaris ATV. Keep this manual with  
the ATV.  
• Never operate an ATV without proper instruction. Take a training course.  
• This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone  
under 16 years of age.  
• Never permit a guest to operate the ATV unless the guest has read this  
manual and all product labels and has completed a certified safety training  
course.  
5
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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. An  
ignition key can be duplicated only by ordering a Polaris key blank  
(using your key number) and mating it with one of your existing keys.  
The ignition switch must be replaced if all keys are lost.  
Engine Serial Number  
####  
VIN  
Key Number  
Vehicle Model Number: ___________________________________________________  
Frame VIN: ____________________________________________________________  
Engine Serial Number: ___________________________________________________  
Key Number: ___________________________________________________________  
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SAFETY  
Safety Training  
ATV safety training is a top priority for Polaris. Polaris strongly  
encourages you and any family members who will be riding the ATV to  
take a training course.  
If you purchased a new Polaris ATV in the United States, your dealer  
provided instruction to you about the authorized ATV RiderCoursesm  
that is available to you and your eligible family members. This training  
is included in the purchase price of your ATV. You were also provided  
with printed materials that explain safe operating procedures. You  
should review this information on a regular basis.  
If you purchased a used Polaris ATV in the United States, you can enroll  
in the ATV RiderCoursesm for a fee. Call ATV Enrollment Express at  
(800) 887-2887 or visit www.atvsafety.org.  
If you purchased a Polaris ATV outside the United States, please contact  
your dealer or local law enforcement agencies for information about  
safety training.  
A Polaris ATV is an off-road vehicle. Familiarize yourself with all laws  
and regulations concerning the operation of this vehicle in your area.  
We strongly advise you to strictly follow the recommended maintenance  
program outlined in your owner's manual. This preventive maintenance  
program is designed to ensure that all critical components on your vehi-  
cle are thoroughly inspected at specific intervals.  
FOR MORE INFORMATION ABOUT ATV SAFETY in the United  
States, call the Consumer Product Safety Commission at 1-800-  
638-2772, or visit www.cpsc.gov, visit www.atvsafety.org, or call  
Polaris at 1-800-342-3764.  
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SAFETY  
Safe Riding Gear  
Always wear appropriate clothing when riding an ATV. Wear protective  
clothing for comfort and to reduce the chance of injury.  
Helmet  
Eye Protection  
Long  
Sleeves  
Gloves  
Long Pants  
Boots  
Helmet  
Wearing a helmet can prevent a severe head injury. Whenever riding a  
Polaris vehicle, always wear a helmet that meets or exceeds established  
safety standards.  
Approved helmets in the USA and Canada bear a U.S. Department of  
Transportation (DOT) label.  
Approved helmets in Europe, Asia and Oceania  
bear the ECE 22.05 label. The ECE mark consists  
4
E
of a circle surrounding the letter E, followed by the  
distinguishing number of the country which has  
granted approval. The approval number and serial  
number will also be displayed on the label.  
051039  
0006.31  
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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.  
Equipment Modifications  
We strongly recommend that consumers do not install on a Polaris ATV  
any equipment that may increase the speed or power of the vehicle, or  
make any other modifications to the vehicle for these purposes.  
The warranty on your Polaris ATV is terminated if any equipment has  
been added to the vehicle, or if any modifications have been made to the  
vehicle, that increase its speed or power.  
The addition of certain accessories, including (but not limited to) mow-  
ers, blades, tires, sprayers, or large racks, may change the handling char-  
acteristics of the vehicle. Use only Polaris-approved accessories, and  
familiarize yourself with their function and effect on the vehicle.  
9
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SAFETY  
Safety Warnings  
WARNING  
Failure to operate the ATV properly can result in a collision, loss of control,  
accident or overturn, which may result in serious injury or death. Heed all safety  
warnings outlined in this section of the owner’s manual. See the OPERATION  
section of the owner’s manual for proper operating procedures.  
Operating Without Instruction  
Operating this ATV without proper instruction  
increases the risk of an accident. The operator  
must understand how to operate the ATV properly  
in different situations and on different types of  
terrain.  
Beginning and inexperienced operators should  
complete the recommended safety training before  
operating this vehicle. See page 7.  
Never permit a guest to operate the ATV unless the  
guest has read this manual and all product labels  
and has completed a certified safety training  
course.  
Age Restrictions  
This vehicle is an ADULT VEHICLE ONLY.  
Operation is prohibited for anyone under 16 years  
of age.  
Even though a child may be within the  
recommended age group for operating some ATVs,  
he/she may not have the skills, abilities, or  
judgment needed to operate an ATV safely and  
could be susceptible to accident or injury.  
10  
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SAFETY  
Safety Warnings  
Handling Gasoline  
Gasoline is highly flammable and explosive under certain conditions.  
• Always exercise extreme caution whenever handling gasoline.  
• Always refuel with the engine stopped, and outdoors or in a well ventilated  
area.  
• Do not smoke or allow open flames or sparks in or near the area where refu-  
eling is performed or where gasoline is stored.  
• Do not overfill the tank. Do not fill the tank neck.  
• If gasoline spills on your skin or clothing, immediately wash it off with soap  
and water and change clothing.  
• Turn the fuel valve off whenever the vehicle is stored or parked.  
Exposure to Exhaust  
Engine exhaust fumes are poisonous and can cause loss of consciousness or  
death in a short time. Never start the engine or let it run in an enclosed area.  
The engine exhaust from this product contains chemicals known to cause  
cancer, birth defects or other reproductive harm. Operate this vehicle only  
outdoors or in well-ventilated areas.  
Failure to Inspect Before Operating  
Failure to inspect and verify that the ATV is in safe  
operating condition before operating increases the  
risk of an accident.  
Always inspect the ATV before each use to make  
sure it's in safe operating condition.  
Always follow all inspection and maintenance  
procedures and schedules described in the  
owner's manual.  
11  
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SAFETY  
Safety Warnings  
Protective Apparel  
Riding in this vehicle without wearing an  
approved helmet and protective eyewear  
increases the risk of a serious injuries in the  
event of an accident.  
Operator and passenger must always wear an  
approved helmet that fits properly and eye  
protection (goggles or face shield).  
Using Alcohol or Drugs  
Operating the ATV after consuming  
alcohol or drugs could adversely affect  
operator judgment, reaction time,  
balance and perception.  
Never consume alcohol or drugs before  
or while operating an ATV.  
Carrying a Passenger  
Carrying a passenger greatly reduces the  
operator's ability to balance and control the  
ATV, which may result in an accident or  
overturn.  
Never carry a passenger on this ATV.  
12  
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SAFETY  
Safety Warnings  
Operating on Pavement  
Operating an ATV on paved surfaces  
(including sidewalks, paths, parking lots and  
driveways) may adversely affect the  
handling of the ATV and could result in loss  
of control and accident or overturn.  
Avoid operating the ATV on pavement. ATV  
tires are designed for off-road use. If it's  
unavoidable, travel slowly and avoid sudden  
turns or stops.  
Operating on Public Roads  
Operating this ATV on public streets, roads  
or highways could result in a collision with  
another vehicle.  
Never operate the ATV on any public street,  
road or highway, including dirt and gravel  
roads. In many states it's unlawful to  
operate ATVs on public streets, roads and  
highways.  
Operating at Excessive  
Speeds  
Operating the ATV at excessive speeds  
increases the operator's risk of losing  
control.  
Always operate at a speed that's  
appropriate for the terrain, the visibility and  
operating conditions, and your experience.  
13  
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SAFETY  
Safety Warnings  
Physical Control of the ATV  
Removing a hand from the handlebars or  
feet from the footrests during operation can  
reduce your ability to control the vehicle or  
cause loss of balance and ejection from the  
ATV. If the operator's foot is not firmly  
planted on the footrest, it could also contact  
the rear wheels.  
Never remove your hands from the  
handlebars while operating, and always  
keep both feet on the footrests.  
Turning Improperly  
Turning improperly could cause loss of  
traction, loss of control, accident or overturn.  
Always follow proper procedures for turning  
as described in the owner's manual.  
Never turn abruptly or at sharp angles. Never  
turn at high speeds. Practice turning at slow  
speeds before attempting to turn at faster  
speeds.  
Jumps and Stunts  
Attempting wheelies, jumps and other  
stunts increases the risk of an accident or  
overturn.  
Never attempt wheelies, jumps, or other  
stunts. Avoid exhibition driving.  
Improper Hill Climbing  
Improper hill climbing could cause loss of  
control or overturn. Always follow proper  
procedures for climbing hills as described in  
the owner's manual. See page 51.  
14  
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SAFETY  
Safety Warnings  
Descending Hills Improperly  
Improperly descending a hill could cause loss  
of control or overturn.  
• Always follow proper procedures for travel-  
ing down hills as described in the owner's  
manual. NOTE: A special technique is  
required when braking while traveling down-  
hill. See page 53.  
• Always descend a hill with the transmission  
in forward gear. Do not descend a hill with  
the transmission in neutral.  
• Always check the terrain carefully before  
descending a hill.  
• Shift your weight rearward.  
• Never travel down a hill at high speed.  
• Avoid traveling down a hill at an angle, which would cause the vehicle to lean  
sharply to one side. Travel straight down the hill when possible.  
Crossing Hillsides  
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 hillside is unavoidable, always follow  
proper procedures as described in the owner's  
manual. See page 52.  
Never attempt to turn the ATV around on any hill  
until you've mastered the turning technique (on  
level ground) as described in the owner's  
manual. See page 54.  
15  
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SAFETY  
Safety Warnings  
Stalling While Climbing a Hill  
Stalling, rolling backwards or improperly  
dismounting while climbing a hill could cause an  
overturn.  
• Always maintain a steady speed when climbing  
a hill.  
If all forward speed is lost:  
• Keep body weight uphill.  
• Apply the brakes.  
• Lock the parking brake when fully stopped.  
• Dismount on uphill side, or to either side if ATV is pointed straight uphill.  
• Turn the ATV around and remount, following the procedure described in the  
owner's manual. See page 54.  
If the ATV begins rolling downhill:  
• Keep body weight uphill.  
• Never apply engine power.  
• Never apply the rear brake while rolling backwards. Apply the single-lever  
brake gradually.  
• When fully stopped, apply the rear brake as well, and then lock the parking  
brake.  
• Dismount on uphill side, or to either side if ATV is pointed straight uphill.  
• Turn the ATV around and remount, following the procedure described in the  
owner's manual. See page 54.  
Operating on Steep Hills  
Operating on excessively steep hills could cause  
an overturn.  
Never operate on hills too steep for the ATV or for  
your abilities. Never operate the ATV on hills  
steeper than 25 degrees.  
16  
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SAFETY  
Safety Warnings  
Operating on Slippery Terrain  
Failure to use extra caution when operating on  
excessively rough, slippery or loose terrain could  
cause loss of traction, loss of control, accident or  
overturn.  
Do not operate on excessively rough, slippery or  
loose terrain. Always use extra caution on rough,  
slippery or loose terrain.  
Operating in Unfamiliar Terrain  
Failure to use extra caution when operating on  
unfamiliar terrain could result in an accident or  
overturn.  
Unfamiliar terrain may contain hidden rocks,  
bumps, or holes that could cause loss of control or  
overturn.  
Travel slowly and use extra caution when operating  
on unfamiliar terrain. Always be alert to changing  
terrain conditions.  
17  
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SAFETY  
Safety Warnings  
Operating Improperly in Reverse  
Improperly operating in reverse could result in a collision with an obstacle or  
person. Always follow proper operating procedures as outlined in this manual.  
See page 57.  
Before shifting into reverse gear, always check for obstacles or people behind  
the ATV. When it's safe to proceed, back slowly.  
Improper Tire Maintenance  
Operating this ATV with improper tires  
or with improper or uneven tire  
pressure could cause loss of control or  
accident.  
Always use the size and type of tires  
specified for your ATV.  
Always maintain proper tire pressure as  
described in the owner's manual and  
on safety labels.  
Operating Over Obstacles  
Improperly operating over obstacles could cause loss of control or overturn.  
Before operating in a new area, check for obstacles. Avoid operating over large  
obstacles such as rocks and fallen trees. If unavoidable, use extreme caution  
and always follow proper operating procedures as outlined in this manual. See  
page 57.  
Skidding or Sliding  
Skidding or sliding can cause loss of control or overturn (if tires regain traction  
unexpectedly).  
On slippery surfaces such as ice or loose gravel, travel slowly and use extra  
caution to reduce the chance of skidding or sliding. Do not operate on  
excessively slippery surfaces.  
18  
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SAFETY  
Safety Warnings  
Operating Through Deep Water  
Operating the ATV through deep or fast-  
flowing water could cause the tires to float,  
causing loss of control or overturn.  
Avoid operating the ATV through deep or  
fast-flowing water. If it's unavoidable to  
enter water that exceeds the  
recommended maximum depth (see page  
55):  
• Travel slowly.  
• Balance your weight carefully.  
• Avoid sudden movements.  
• Maintain a slow and steady forward motion. Do not make sudden turns or  
stops, and do not make sudden throttle changes.  
• Wet brakes may have reduced stopping ability. After leaving water, test the  
brakes. Apply them lightly several times while driving slowly. The friction will  
help dry out the pads.  
Improper Cargo Loading  
Overloading the ATV or carrying/towing cargo improperly may cause changes in  
handling, which could cause loss of control or an accident.  
• Never exceed the stated load capacity for this ATV.  
• Cargo should be properly distributed and securely attached.  
• Reduce speed when carrying cargo or pulling a trailer. Allow a greater dis-  
tance for braking.  
• Always follow the instructions in the owner's manual for carrying cargo or pull-  
ing a trailer.  
19  
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SAFETY  
Safety Warnings  
Operating on Frozen Bodies of Water  
Operating on frozen bodies of water may result in serious injury or death if the  
ATV and/or the operator fall through the ice.  
Never operate the ATV on a frozen body of water.  
Poor Visibility  
Operating the ATV in darkness or inclement weather could result in a collision or  
accident, especially if operating on a road or street. This ATV is not equipped  
with highway-approved lights. Operate this vehicle off-road only. Use caution  
and drive at reduced speeds in conditions of reduced visibility such as fog, rain  
and darkness. Clean headlights frequently and replace burned out headlamps  
promptly.  
Operating a Damaged ATV  
Operating a damaged ATV can result in an accident. After any overturn or  
accident, have a qualified service dealer inspect the entire machine for possible  
damage, including (but not limited to) brakes, throttle and steering systems.  
Physical Skills  
Safe operation of this rider-active vehicle requires good judgement and physical  
skills. Persons with cognitive or physical disabilities who operate this vehicle  
have an increased risk of overturn and loss of control.  
Hot Exhaust Systems  
Exhaust system components are very hot during and after use of the vehicle.  
Hot components can cause burns and fire. Do not touch hot exhaust system  
components. Always keep combustible materials away from the exhaust  
system. Use caution when traveling through tall grass, especially dry grass.  
Unauthorized Use of the ATV  
Leaving the keys in the ignition can lead to unauthorized use of the vehicle,  
which could result in an accident or overturn. Always remove the ignition key  
when the vehicle is not in use.  
20  
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SAFETY  
Safety Decals 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/Discretionary 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  
terrain and in turns  
• avoid paved surfaces - pavement may seriously affect handling and control  
LOCATE AND READ OPERATOR’S MANUAL.  
FOLLOW ALL INSTRUCTIONS AND WARNINGS.  
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.  
7175550  
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SAFETY  
Safety Decals and Locations  
Age 16 Warning  
General Warning  
Discretionary Warning  
“No Passenger”  
Warning  
+
+
+
+
Tire Pressure/Load  
Warning  
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: 5.0 psi (34.5 kPa)  
Rear: 5.0 psi (34.5 kPa)  
• Maximum weight capacity: 485 lbs. (220 kg)  
7175642  
“No Passenger” Warning  
WARNING  
NEVER ride as a passenger.  
Passengers can cause a loss of control, resulting in SEVERE INJURY or  
DEATH.  
7175378  
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.  
7175551  
22  
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SAFETY  
Safety Decals and Locations  
Rack  
Warning  
Rack  
Warning  
+
+
+
Clutch Cover  
Warning  
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  
Rack Warning, Front and Rear  
WARNING  
• DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may  
result causing severe injury or death. Tow only from tow hooks or hitch.  
• Max Rack Loads: Front 90 lbs. (41 kg) Rear 180 lbs. (82 kg)  
7172572  
Reverse Override Warning/4X4 Caution  
WARNING  
Improper use of override button can lead to loss of control resulting in serious  
injury or death. Do not activate override while throttle is engaged. Always apply  
throttle gradually while in reverse.  
CAUTION  
Do not push switch to engage 4X4 (AWD) if the rear wheels are spinning. This  
may cause severe drive shaft and clutch damage.  
7175552  
23  
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FEATURES AND CONTROLS  
Switches  
Headlight  
Switch  
AWD Switch  
Main Key Switch  
Choke  
Mode/Reverse  
Override  
Switch  
Engine  
Stop Switch  
Mode/Reverse Override Switch  
This vehicle is equipped with a reverse speed limiter system. To gain  
additional wheel speed while backing, release the throttle and depress  
the override button.  
WARNING! Pressing the override button 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 button.  
The override switch also allows activation of 4X4 in reverse, if the 4X4  
switch is on. This switch is also used to toggle through the modes of the  
rider information center. See page 34.  
AWD Switch  
Use the AWD switch to engage 4X4 or 2X4. See page 33.  
24  
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FEATURES AND CONTROLS  
Switches  
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 electri-  
cal power to the vehicle, including lights.  
Main Key Switch  
Use the main key switch to start the engine. See page 46 for starting pro-  
cedures.  
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.  
25  
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FEATURES AND CONTROLS  
Throttle Lever  
WARNING  
Operating an ATV with sticking or improperly operating throttle controls could  
cause an accident. Never start or operate an ATV that has a sticking or  
improperly operating throttle. Always contact your dealer for service before  
operating the vehicle.  
Failure to check or maintain proper operation of the throttle system can result in  
an accident if the throttle lever sticks during operation. Always check the lever  
for free movement and return before starting the engine. Also check  
occasionally during operation.  
Modifications to the electronic throttle control could result in failure to perform as  
designed, which could result in an accident. Do not attempt to modify the throttle  
control system or replace it with any after market throttle mechanisms. Always  
ensure that the throttle cable is installed and properly routed to the throttle  
control.  
Engine speed and vehicle move-  
ment are controlled by pressing the  
throttle lever. The throttle lever is  
spring loaded. Engine speed returns  
to idle when the lever is released.  
This ATV is equipped with Polaris  
Electronic Throttle Control (ETC),  
which is designed to reduce the risk  
of a frozen or stuck throttle. If the  
throttle cable should stick in an  
open position when the operator releases the throttle lever, the engine  
will stop, and power to the rear wheels will cease.  
26  
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FEATURES AND CONTROLS  
Brake Lever  
WARNING  
Operating the ATV with a spongy brake lever can result in loss of braking, which  
could cause an accident. Never operate the ATV with a spongy-feeling brake  
lever. Always contact your dealer for service before operating the vehicle.  
Squeeze the brake lever toward the  
handlebar to apply the front and  
rear brakes. These brakes are  
hydraulically activated disc type  
brakes that are activated by only  
one lever.  
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.  
27  
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FEATURES AND CONTROLS  
Master Cylinder/Brake Fluid  
WARNING  
An over-full master cylinder may cause brake drag or brake lock-up, which could  
result in an accident. Maintain brake fluid at the recommended level. Do not  
overfill.  
Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic,  
meaning it rapidly absorbs moisture from the air. The moisture causes the  
boiling temperature of the brake fluid to drop, which can lead to early brake fade  
and the possibility of brake failure, which could result in an accident. After  
opening a bottle of brake fluid, always discard any unused portion.  
Check the brake fluid in the master  
cylinder before each ride.  
Master Cylinder  
1. Position the ATV on a level  
surface.  
2. Position the handlebars so the  
master cylinder is level.  
3. View the brake fluid level  
through the indicator window  
on the top of the master cylin-  
der. The eye will appear dark  
when the fluid level is full.  
Indicator  
Window  
When fluid is low, the eye will be clear.  
4. If the fluid level is low add DOT 4 brake fluid only. Do not overfill.  
28  
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FEATURES AND CONTROLS  
Parking Brake  
Locking the Parking Brake  
1. Place the transmission in  
PARK.  
2. Squeeze and release the brake  
lever two or three times, then  
squeeze and hold.  
3. Push the parking brake lock  
forward to engage the lock.  
4. Release the brake lever.  
5. To release the parking brake lock, squeeze and release the brake  
lever. It will return to its unlocked position.  
WARNING! Operating the ATV while the parking brake is engaged could result  
in an accident or fire. 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 ATV if leaving it parked on a hill. Another option is  
to park the ATV in a sidehill position. Never depend on the parking  
brake alone if the ATV is parked on a hill. Always block the wheels to  
prevent rolling.  
29  
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FEATURES AND CONTROLS  
Auxiliary Foot Brake  
WARNING  
Aggressively applying the auxiliary brake when backing down a hill may cause  
rear tipover, which could result in serious injury or death. Never back down a hill.  
Use caution when applying the auxiliary brake. Do not aggressively apply the  
auxiliary brake when going forward. The rear wheels may skid and slide  
sideways, causing loss of control, which may result in serious injury or death.  
The auxiliary brake system is intended to be used as a backup for the  
main brake system. Should the main system fail, use the auxiliary foot  
brake. Since this is a rear brake only, it will not be as effective as the all-  
wheel single lever system.  
The auxiliary foot brake is located  
on the inside of the right footrest.  
Operate this brake with your right  
foot.  
Auxiliary Foot Brake  
If the rear wheels slide while using  
the auxiliary brake, reduce brake  
pedal pressure to brake the rear  
wheels without skidding.  
Brake Fluid Level  
Check the brake fluid level frequently for the auxiliary brake system.  
The reservoir is located near the auxiliary brake. Maintain the fluid level  
between the maximum and minimum marks.  
30  
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FEATURES AND CONTROLS  
Choke  
The choke assists in starting a cold engine. Refer to the engine starting  
procedure on page 46 for correct choke and throttle settings during start-  
ing.  
Fuel Valve  
The fuel valve is located under the  
front storage box cover.  
OFF: For vehicle storage and when  
transporting.  
ON  
OFF  
ON: For normal operation.  
Fuel Tank Cap  
Fuel  
Tank  
Cap  
This vehicle is equipped with a  
digital fuel gauge that will  
indicate a low fuel condition.  
Refuel when the gauge indi-  
cates a low fuel condition.  
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 fuel with ethanol content greater than 10 percent,  
such as E-85 fuel.  
Fuel Filter  
The in-line fuel filter should be replaced by your dealer after every 100  
hours of operation, or annually. Do not attempt to clean the fuel filter.  
31  
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FEATURES AND CONTROLS  
Automatic Transmission Gear Selector  
The transmission gear  
selector is located on the  
right side of the vehicle.  
Gear  
Selector  
H: High Gear  
L: Low Gear  
N: Neutral  
R: Reverse  
P: Park  
To shift gears, brake to a  
complete stop. When the  
engine is idling, move the  
lever to the desired gear.  
NOTICE: Shifting gears with  
the engine speed above idle or while the vehicle is moving could  
cause transmission damage.  
Whenever the ATV is left unattended, always place the transmission in  
PARK and lock the parking brake.  
Belt Life  
To extend belt life, use low forward gear in heavy pulling situations and  
when operating at less than seven miles per hour for extended periods of  
time.  
32  
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FEATURES AND CONTROLS  
All Wheel Drive (AWD) System  
The All Wheel Drive system is  
controlled by the AWD switch.  
When the switch is on 2X4, the  
ATV is in two-wheel drive at all  
times. When the switch is on  
AWD, the ATV is in all wheel  
drive and the AWD indicator light  
in the instrument cluster will be  
on.  
AWD  
Switch  
When in AWD, the demand drive unit will automatically engage any  
time the rear wheels lose traction. When the rear wheels regain traction,  
the demand drive unit will automatically disengage.  
Tip: The override switch allows activation of AWD in reverse if the AWD switch  
is on. See page 24.  
There is no limit to the length of time the vehicle may remain in AWD.  
Engaging AWD  
The AWD switch may be turned on or off while the vehicle is moving.  
Initially, the vehicle's electronic system will not enable the AWD until  
the engine RPM is below 3100. Once enabled, the AWD remains  
enabled until the AWD switch is turned off. If the switch is turned off  
while the demand drive unit is moving, it will not disengage until the  
rear wheels regain traction.  
Engage the AWD switch before getting into conditions where front  
wheel drive may be needed. If the rear wheels are spinning, release the  
throttle before switching to AWD.  
33  
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FEATURES AND CONTROLS  
Instrument Cluster  
Your ATV is equipped with an instrument cluster that senses vehicle  
speed from the right front wheel. In addition to showing vehicle speed,  
the speedometer needle flashes when a warning condition exists.  
The instrument cluster measures distance in miles as well as hours of  
operation. It also includes a reverse speed limiter function that limits the  
ATV's speed to approximately 7-9 mph (11-14 km/h). Refer to page 24  
for additional information.  
Speedometer  
Needle  
Speedometer  
Rider  
Information  
Center  
NOTICE: High water pressure may damage ATV components. Wash the ATV  
by hand or with a garden hose using mild soap.  
Certain products, including insect repellents and chemicals, will  
damage the speedometer lens and other plastic surfaces. Do not use  
alcohol to clean the instrument cluster. Do not allow insect sprays to  
contact the lens. Immediately clean off any gasoline that splashes on  
the instrument cluster.  
34  
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FEATURES AND CONTROLS  
Instrument Cluster  
Rider Information Center  
The rider information center is located in the instrument cluster. All seg-  
ments will light up for 2.5 seconds at start-up. If the instrument cluster  
fails to illuminate, a battery over-voltage may have occurred and the  
instrument cluster may have shut off to protect the electronic speedome-  
ter. If this occurs, take the ATV to your Polaris dealer for proper diagno-  
sis.  
1. Gear Indicator - This  
indicator displays gear  
shifter position:  
H = High Gear  
6
3
4
5
7
8
L = Low Gear  
N = Neutral  
R = Reverse Gear  
P = Park  
2
2. AWD Indicator - This  
indicator illuminates  
9
when the AWD switch  
is in the AWD position.  
1
3. Engine Hour Display Indicator  
4. Service Interval/Diagnostic Mode Indicator  
5. Low Battery and Over Voltage - This warning usually indicates  
that the ATV is operating at an RPM too low to keep the battery  
charged. It may also occur when the engine is at idle and high elec-  
trical load (lights, cooling fan, accessories) is applied. Drive at a  
higher RPM or recharge the battery to clear the warning.  
6. Odometer/Tachometer/Tripmeter/ Hour Meter  
7. Fuel Gauge - The segments of the fuel gauge show the level of fuel  
in the fuel tank. When the last segment clears, a low fuel warning is  
activated. All segments will flash, FUEL will display in the LCD,  
and the speedometer needle will blink. Refuel immediately.  
8. Check Engine Warning Indicator - The word HOT displays if the  
engine overheats. Do not operate the ATV if this warning appears.  
Serious engine damage could result.  
9. Mode Indicator  
35  
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FEATURES AND CONTROLS  
Instrument Cluster  
Rider Information Center  
Standard Modes  
Use the MODE button to toggle through the mode options. The reverse  
override button is also the MODE button. See page 24. The transmission  
cannot be in reverse when using this feature.  
Odometer Mode  
The odometer records the miles traveled by the ATV.  
Trip Meter Mode  
The trip meter records the miles traveled by the ATV on each trip if it's  
reset before each trip. To reset the trip meter, select the trip meter mode.  
Press and hold the mode button (override button) until the total changes  
to 0. In the Rider Information Center, the trip meter display contains a  
decimal point, but the odometer displays without a decimal point.  
Hour Meter Mode  
This mode logs the total hours the engine has been in operation.  
Tachometer Mode  
The engine RPM is displayed digitally. Small fluctuations in the RPM  
from day to day may be normal because of changes in humidity, temper-  
ature and elevation.  
36  
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FEATURES AND CONTROLS  
Instrument Cluster  
Rider Information Center  
Diagnostic Mode  
The wrench icon will display when the gauge is in the diagnostic mode.  
To exit the diagnostic mode, turn the key switch off and on. Any move-  
ment of the tires will also cause the gauge to exit the diagnostic mode.  
To enter the diagnostics mode:  
1. Turn the key switch off and wait 10 seconds.  
2. Lock the parking brake.  
3. Place the transmission in neutral.  
4. Hold the mode/reverse override button and turn the key switch on.  
Release the switch as soon as the display is activated.  
5. Use the mode button to toggle through the diagnostic screens.  
37  
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FEATURES AND CONTROLS  
Instrument Cluster  
Rider Information Center  
Diagnostic Mode  
Battery Voltage Screen  
View this screen to check battery voltage level.  
Tachometer Screen  
View the tachometer to check engine speed.  
AWD Diagnostic Screen  
The gauge indicates whether or not current is flowing through the AWD  
coil (only on models with switchable AWD). This screen is for informa-  
tional purposes only. Please see your dealer for all major repairs.  
Gear Circuit Diagnostic Screen  
This screen displays the resistance value (in ohms) being read at the  
gear switch input of the gauge. This screen is for informational purposes  
only. Please see your dealer for all major repairs.  
Programmable service interval  
When the hours of engine operation equal the programmed service  
interval setting, the wrench icon will flash for 5 seconds each time the  
engine is started. When this feature is enabled, it provides a convenient  
reminder to perform routine maintenance. See page 39.  
The service interval is programmed at 50 hours at the factory.  
38  
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FEATURES AND CONTROLS  
Instrument Cluster  
Rider Information Center  
Diagnostic Mode  
Programmable service interval  
To enable or disable the service interval:  
1. Enter the diagnostic mode.  
2. Toggle to the service interval screen.  
3. Press and hold the mode button for about 7 seconds, until either ON  
or OFF appears in the Rider Information Center, depending on your  
preference.  
To reset the service interval:  
1. Enter the diagnostic mode.  
2. Toggle to the service interval screen.  
3. Press and hold the mode button for 2-3 seconds, until the wrench  
icon flashes. Release the button.  
4. Press and release the mode button once to advance the setting by  
one hour. Press and hold the mode button to advance the hours  
quickly.  
5. If you scroll past the intended number, press and hold the button  
until the hours cycle back to zero.  
6. When the desired setting is displayed, wait until the wrench icon  
stops flashing. The new service interval is now programmed.  
39  
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FEATURES AND CONTROLS  
Instrument Cluster  
Rider Information Center  
Diagnostic Mode  
Miles/Kilometers toggle  
The display in the tripmeter and odometer can be changed to display  
either standard or metric units of measurement.  
1. Enter the diagnostic mode.  
2. Toggle to the screen that displays either kilometers (KM) or miles  
(MP).  
3. Press and hold the mode button until the letters flash, then press and  
release the button once. When the display stops flashing, the mode  
has been set.  
40  
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OPERATION  
WARNING  
Failure to operate the ATV properly can result in a collision, loss of control,  
accident or overturn, which may result in serious injury or death. Read and  
understand all safety warnings outlined in the safety section of this owner’s  
manual.  
Break-In Period  
The break-in period for your new Polaris ATV is the first ten hours of  
operation, or the time it takes to use the first two full tanks of gasoline.  
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: Excessive heat build-up during the first three hours of operation will  
damage close-fitted engine parts and drive components. Do not  
operate at full throttle or high speeds during the first three hours of  
use.  
41  
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OPERATION  
Break-In Period  
Engine and Drivetrain Break-in  
1. Fill the fuel tank with gasoline. See page 31. Always exercise  
extreme caution whenever handling gasoline.  
2. Check the oil level on the dipstick. See page 69. Add oil if neces-  
sary to maintain the level between the safe and add marks.  
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 45.  
6. Pull only light loads.  
7. During the break-in period, change both the oil and the filter at 20  
hours or one month.  
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.  
42  
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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 ATV.  
4. Engine exhaust fumes are poisonous. Never start the engine or let it  
run in an enclosed area.  
5. Before operating, learn how to use the auxiliary brake for emer-  
gency situations (if service brakes become inoperable).  
6. Operate this vehicle off-road only. Never operate the vehicle on  
pavement or on any public street, road or highway, including dirt  
and gravel roads.  
7. 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.  
8. 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.  
9. Never consume alcohol or drugs before or while operating an ATV.  
10. Always use the size and type of tires specified for your vehicle.  
Always maintain proper tire pressure.  
11. Never operate a damaged ATV. After any overturn or accident, have  
a qualified service dealer inspect the entire machine for possible  
damage.  
12. Never operate the ATV on a frozen body of water.  
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.  
43  
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OPERATION  
Know Your Riding Area/Tread Lightly  
Familiarize yourself with all laws and regulations concerning the opera-  
tion of this off-road vehicle in your area. Respect the environment in  
which you ride. Find out where the designated riding areas are by con-  
tacting your Polaris dealer, a local riding club or local officials.  
Help keep our trails open for recreational vehicle use. As an off-road  
enthusiast, you represent the sport and can set a good example (or a poor  
example) for others to follow. Tread lightly. Operate with respect for the  
terrain, avoid littering, and always stay on the designated trails.  
Trail Etiquette  
Always practice good etiquette when riding. Allow a safe distance  
between your vehicle and other vehicles operating in the same area.  
Communicate to oncoming operators by signaling the number of vehi-  
cles in your group. When stopping, move your vehicle to the edge of the  
trail as far as possible to allow others to pass safely.  
44  
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OPERATION  
Pre-Ride Checklist  
Failure to inspect and verify that the ATV is in safe operating condition  
before operating increases the risk of an accident. Always inspect the  
ATV before each use to make sure it's in safe operating condition.  
Item  
Remarks  
Page  
Brake system/lever travel  
Ensure proper operation  
27  
78  
Brake fluid  
Ensure proper level  
28  
30  
67  
67  
-
Auxiliary brake  
Front suspension  
Rear suspension  
Steering  
Ensure proper operation  
Inspect, lubricate if necessary  
Inspect, lubricate if necessary  
Ensure free operation  
Tires  
Inspect condition and pressure  
Inspect, ensure fastener tightness  
81  
Wheels/fasteners  
81  
82  
Frame nuts, bolts, fasteners Inspect, ensure tightness  
-
Fuel and oil  
Ensure proper levels  
31  
69  
Coolant level (if applicable)  
Ensure proper level  
76  
77  
Coolant hoses (if applicable) Inspect for leaks  
-
Throttle  
Ensure proper operation  
26  
105  
Indicator lights/switches  
Engine stop switch  
Air filter, pre-filter  
Air box sediment tube  
Headlamp  
Ensure operation  
24  
25  
83  
-
Ensure proper operation  
Inspect, clean  
Drain deposits whenever visible  
Check operation, apply Polaris dielec-  
tric grease when lamp is replaced  
25  
86  
Brake light/taillight  
Riding gear  
Check operation, apply Polaris dielec-  
tric grease when lamp is replaced  
89  
Wear approved helmet, goggles, and  
protective clothing  
8
45  
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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 PARK.  
3. Lock the parking brake.  
Tip: The starter interlock will prevent the engine from starting if the transmission  
is in gear and the brake is not engaged.  
4. Turn the fuel valve on.  
5. Sit on the vehicle.  
6. Do not use the choke if starting a warm engine. Excessive use of the  
choke can cause the spark plug to become wet fouled.  
7. If the engine is cold, pull the  
choke knob out until it stops.  
Tip: The variable choke is fully on  
when the knob is pulled com-  
pletely out. The choke is off when  
the knob is pushed completely in.  
The choke can be adjusted gradu-  
ally, depending on how much  
choke is needed for starting. Be  
sure the choke is off during opera-  
tion, as excess fuel washing into  
the engine oil will increase wear  
on engine components.  
8. If the knob doesn't stay where  
Tension  
Adjusting Nut  
positioned, increase the ten-  
sion by rotating the tension  
adjusting nut clockwise.  
9. Move the engine stop switch to RUN.  
10. Do not press the throttle while starting the engine.  
46  
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OPERATION  
Starting the Engine  
11. Turn the ignition key past the ON position to engage the starter.  
Activate the starter for a maximum of five seconds, releasing the  
key when the engine starts.  
NOTICE: Operating the vehicle immediately after starting could cause engine  
damage. Allow the engine to warm up for several minutes before  
operating the vehicle.  
12. If the engine does not start, return the key to the OFF position and  
wait five seconds before attempting to start again. 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 button (pulled half way out) may be necessary. If  
the engine is over-choked when warm, depress the throttle lever fully while  
cranking to aid in starting. Release the throttle lever immediately after the  
engine starts. If the engine does not start and all conditions are favorable,  
change the spark plug and try again.  
13. 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.  
Cold Weather Operation  
If the ATV is used year-round, check the oil level frequently. A rising oil  
level could indicate the accumulation of contaminates such as water or  
excess fuel in the bottom of the crankcase. Water in the bottom of the  
crankcase can lead to engine damage and must be drained. Water accu-  
mulation increases as outside temperature decreases.  
See your Polaris dealer for engine heater kits, which provide quicker  
warm-ups and easier starting in colder weather.  
47  
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OPERATION  
Driving Procedures  
1. Wear a helmet and eye protection. See page 8.  
2. Sit upright with both feet on the footrests and both hands on the  
handlebars.  
3. Start the engine and allow it to warm up.  
4. Shift the transmission into gear.  
5. Check your surroundings and determine your path of travel.  
6. Release the parking brake.  
7. Slowly depress the throttle with your right thumb and begin driving.  
8. Drive slowly. Practice maneuvering and using the throttle and  
brakes on level surfaces.  
48  
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OPERATION  
Turning the Vehicle  
Your ATV is equipped with  
a solid rear axle, which  
drives both rear wheels  
equally at all times. This  
means that the wheel on the  
outside of the turn must  
travel a greater distance  
than the inside wheel when  
turning and the inside tire  
must slip traction slightly.  
To turn, steer in the direc-  
tion of the turn, leaning  
your upper body to the  
inside of the turn while  
supporting your weight on  
the outer footrest. This  
technique alters the balance  
of traction between the rear  
wheels, allowing the turn to be made smoothly. The same leaning tech-  
nique should be used for turning in reverse.  
Practice making turns at slow speeds before attempting to turn at faster  
speeds.  
WARNING! Turning improperly can result in vehicle overturn. Never turn  
abruptly or at sharp angles. Never turn at high speeds.  
49  
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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. Engage AWD before wheels begin to lose traction.  
NOTICE: Severe damage to drive train may occur if the AWD is engaged while  
the wheels are spinning. Allow the rear wheels to stop spinning  
before engaging AWD, or engage AWD before wheels begin to lose  
traction.  
4. Maintain a high level of alertness, reading the trail and avoiding  
quick, sharp turns, which can cause skids.  
5. 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.  
50  
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OPERATION  
Driving Uphill  
25° Maximum  
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 terrain carefully before ascending any hill.  
4. Never climb hills with excessively slippery or loose surfaces.  
5. Keep both feet on the footrests.  
6. Shift your weight uphill.  
7. Proceed at a steady rate of speed and throttle opening. Opening the  
throttle suddenly could cause the ATV to flip over backwards.  
8. Remain alert and be prepared to take emergency action. This may  
include quick dismounting of the vehicle.  
51  
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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 crossing the side of a steep hill.  
3. Shift body weight uphill.  
4. Keep your feet on the footrests.  
5. Steer slightly into the hill to maintain vehicle direction.  
6. If the vehicle begins to tip, quickly turn the front wheel downhill, if  
possible, or dismount on the uphill side immediately!  
52  
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OPERATION  
Driving Downhill  
When driving downhill, follow these precautions:  
1. Avoid steep hills (25° maximum).  
2. Shift body weight uphill.  
3. Drive straight downhill.  
4. Slow down. Excessive speed when traveling downhill can cause  
loss of control.  
5. 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.  
53  
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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.  
8 ft. (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.  
54  
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OPERATION  
Driving Through Water  
Your ATV can operate through  
water with a maximum recom-  
mended depth equal to the bot-  
tom of the footrests. Follow  
these procedures when operat-  
ing through water:  
1. Determine water depths and  
current before entering  
water.  
2. Choose a crossing where  
both banks have gradual  
inclines.  
Maximum  
Depth  
3. Avoid operating through  
deep or fast-flowing water.  
NOTICE: Major engine damage can result if the vehicle is not thoroughly  
inspected after operation in water. Perform the services outlined in  
the maintenance chart. See page 62. The following areas need  
special attention: engine oil, transmission oil, demand drive fluid, rear  
gearcase oil, 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 92,  
then see your dealer for service at the first opportunity.  
4. After leaving water, test the brakes. Apply them lightly several  
times while driving slowly. The friction will help dry out the pads.  
If its unavoidable to enter water deeper than the footrest level:  
• Proceed slowly. Avoid rocks and obstacles.  
• Balance your weight carefully. Avoid sudden movements.  
• Maintain a steady rate of speed. Do not make sudden turns or stops.  
Do not make sudden throttle changes.  
55  
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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. Look ahead and learn to read the terrain. Be constantly alert for haz-  
ards such as logs, rocks and low hanging branches.  
3. Travel slowly and use extra caution when operating on unfamiliar  
terrain. Not all obstacles are immediately visible.  
4. Never attempt to operate over large obstacles, such as rocks or  
fallen trees.  
56  
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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 button 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.  
57  
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OPERATION  
Hauling Cargo  
WARNING  
Overloading the vehicle or carrying or towing cargo improperly can alter vehicle  
handling and may cause loss of control or brake instability, which can result in  
serious injury or death. Always follow these precautions when hauling cargo:  
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.  
58  
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OPERATION  
Hauling Cargo  
Never exceed the weight capac-  
ities specified for your ATV on  
warning labels and in the speci-  
fications section of this manual.  
2/3  
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. Use low forward  
gear when hauling or towing heavy cargo to extend belt life.  
Towing Loads  
Always attach a towed load to the hitch point. Remove the hitch from  
the ATV when not towing a trailer. If towing a load, reduce rear rack  
cargo weight by the amount of tongue weight.  
• The combination of rear rack cargo weight and tongue weight must  
not exceed the rear rack capacity.  
• The total load (operator, accessories, cargo and weight on hitch) must  
not exceed the maximum weight capacity of the vehicle.  
NOTICE: Using an improper hitch or exceeding  
the maximum tongue weight capacity  
can result in serious damage to the  
vehicle and will void your ATV  
Maximum  
4" (10 cm)  
warranty. Never install a hitch longer  
than 4" (10 cm). Never install  
automotive accessories on your  
Polaris ATV. Always install Polaris-  
approved (or equivalent) accessories  
designed for ATV use.  
59  
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OPERATION  
Parking on an Incline  
Avoid parking on an incline if possible. If it's unavoidable, follow these  
precautions:  
1. Stop the engine.  
2. Place the transmission in PARK.  
3. Lock the parking brake.  
4. Always block the rear wheels on the downhill side.  
5. Turn the fuel valve off.  
60  
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EMISSION CONTROL SYSTEMS  
Noise Emission Control System  
Do not modify the engine, intake or exhaust components, as doing so  
may affect compliance with U.S.A. EPA noise control requirements (40  
CFR 205) and local noise level requirements.  
Operation on Public Lands in the U.S.A.  
Your Polaris vehicle has a spark arrestor that was tested and qualified to  
be in accordance with the USFS standard 5100-1c. Federal law requires  
that this spark arrestor be installed and functional when the vehicle is  
operated on public lands.  
Operation of off-road vehicles on public lands in the U.S.A. is regulated  
by 43 CFR 420. Violations are subject to monetary penalties. Federal  
regulations can be viewed online at www.gpoaccess.gov/ecfr/.  
Crankcase Emission Control System  
This engine is equipped with a closed crankcase system. Blow-by gases  
are forced back to the combustion chamber by the intake system. All  
exhaust gases exit through the exhaust system.  
Exhaust Emission Control System  
The emissions from the exhaust of this vehicle are controlled by engine  
design, including factory-set fuel delivery and ignition. The engine and  
related components must be maintained at Polaris specifications to  
achieve optimal performance.  
Engine idle speed is the only adjustment Polaris recommends that the  
operator perform. Any other adjustments should be performed by an  
authorized Polaris dealer.  
The vehicle compliance labels can be found on the frame tubing of the  
vehicle.  
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.  
61  
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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 129.  
Service and adjustments are important for proper vehicle operation. If  
you're not familiar with safe service and adjustment procedures, have a  
qualified dealer perform these operations.  
Maintenance intervals in the following chart are based upon average  
riding conditions and an average vehicle speed of approximately 10  
miles per hour. Vehicles subjected to severe use must be inspected and  
serviced more frequently.  
Severe Use Definition  
• 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.  
62  
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MAINTENANCE  
Periodic Maintenance Chart  
WARNING  
Improperly performing the procedures marked with a could result in  
component failure and cause an accident, which may result in serious injury or  
death. Always have an authorized Polaris dealer perform these services.  
Maintenance Chart Key  
X
Perform these operations more often for vehicles subjected to  
severe use.  
E
Emission-related service (Failure to conduct this maintenance will  
not void the emissions warranty but may affect emissions.)  
Q
Have an authorized Polaris dealer perform these services.  
63  
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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  
Miles  
(Km)  
Q
Steering  
-
-
-
-
-
-
-
-
-
-
-
Pre-Ride  
Pre-Ride  
Pre-Ride  
Pre-Ride  
Pre-Ride  
Pre-Ride  
Pre-Ride  
Pre-Ride  
Pre-Ride  
Pre-Ride  
Daily  
-
-
-
-
-
-
-
-
-
-
-
Make adjustments as need  
ed. See Pre-Ride Checklist  
on page 45.  
X Front suspension  
X Rear suspension  
Tires  
X Brake fluid level  
X Brake lever travel  
Brake system  
Wheels/fasteners  
Frame fasteners  
X Engine oil level  
X Air filter, pre-filter  
E
Inspect; clean often; replace  
as needed  
X Air box sediment  
-
-
-
Daily  
Daily  
Daily  
-
-
-
Drain deposits when visible  
tube  
Coolant  
Check level daily, change  
coolant every 2 years  
Headlight/taillight/  
worklight  
Check operation; apply  
dielectric grease if replacing  
lamps  
X Air filter,  
-
-
Weekly  
Weekly  
-
-
Inspect; replace as needed  
E main element  
Recoil housing  
Drain water as needed,  
check often if operating in wet  
conditions  
X Brake pad wear  
10 H  
20 H  
Monthly  
100 (160) Inspect periodically  
Q
Battery  
Monthly  
Monthly  
Monthly  
200 (320) Check terminals; clean; test  
250 (400) Inspect level; change yearly  
250 (400) Inspect level; change yearly  
X Demand drive fluid 25 H  
X Rear gearcase oil  
25 H  
(if equipped)  
X Transmission oil  
25 H  
25 H  
Monthly  
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.  
64  
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MAINTENANCE  
Periodic Maintenance Chart  
Item  
Maintenance Interval  
Remarks  
(whichever comes first)  
Hours Calendar  
Miles  
(Km)  
X General  
50 H  
50 H  
50 H  
3 M  
6 M  
6 M  
500 (800) Lubricate all fittings, pivots,  
cables, etc.  
lubrication  
Carburetor float  
bowl  
500 (800) Drain bowl periodically and  
prior to storage  
Q
E
Throttle Cable/  
ETC Switch  
500 (800) Inspect; adjust; lubricate;  
replace if necessary  
Q
E
Choke cable  
50 H  
50 H  
50 H  
50 H  
6 M  
6 M  
6 M  
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 H  
6 M  
1000 (1600) Perform a break-in oil change  
at one month  
X Oil filter change  
100 H  
100 H  
6 M  
1000 (1600) Replace with oil change  
1000 (1600) Inspect; adjust  
Q
Valve clearance  
12 M  
E
Q
E
Fuel system/filter  
100 H  
12 M  
1000 (1600) Check for leaks at tank cap,  
lines, fuel valve, filter, pump,  
carburetor; replace lines  
every two years  
X Radiator  
100 H  
100 H  
12 M  
12 M  
1000 (1600) Inspect; clean external  
surfaces  
(if applicable)  
X Cooling hoses  
1000 (1600) Inspect for leaks  
(if applicable)  
X Engine mounts  
100 H  
100 H  
12 M  
12 M  
1000 (1600) Inspect  
1000 (1600) Inspect  
Exhaust muffler/  
pipe  
Q
E
Q
E
Spark plug  
100 H  
100 H  
100 H  
12 M  
12 M  
12 M  
1000 (1600) Inspect; replace as needed  
1000 (1600) Inspect  
Ignition timing  
X Wiring  
1000 (1600) Inspect for wear, routing,  
security; apply dielectric  
grease to connectors  
subjected to water, mud, etc.  
65  
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MAINTENANCE  
Periodic Maintenance Chart  
Item  
Maintenance Interval  
Remarks  
(whichever comes first)  
Hours Calendar  
Miles  
(Km)  
Q
Q
Q
Clutches (drive  
and driven)  
100 H  
100 H  
12 M  
12 M  
1000 (1600) Inspect; clean; replace worn  
parts  
Front wheel  
bearings  
1000 (1600) Inspect; replace as needed  
Brake fluid  
200 H  
300 H  
24 M  
36 M  
2000 (3200) Change every two years  
3000 (4800) Clean out  
Spark arrestor  
Idle speed  
-
Adjust as needed  
Q
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.  
66  
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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 62. Items not listed in the  
chart should be lubricated at the General Lubrication interval.  
The a-arms and lower control arms are lubricated at the factory, and no  
additional lubrication will be needed. However, if these components are  
subjected to severe use, grease zerks have been provided for additional  
lubrication at the user's discretion.  
Item  
Lube  
Capacity at  
Fluid Change  
Inspection Procedure  
Engine Oil  
Polaris Premium 4  
Synthetic 0W40  
2 qt. (1.9 l)  
---  
Maintain level in safe range  
on dipstick. See page 69.  
Brake Fluid  
DOT 4 Only  
Maintain level between fill  
lines. See page 28.  
Transmission Oil  
Polaris AGL  
Synthetic  
Gearcase Lube  
32 oz. (948 ml) Maintain level at bottom of fill  
hole threads. See page 73.  
Demand Drive  
Fluid  
(Front Gearcase)  
Demand Drive  
Plus Fluid  
9 oz. (265 ml) Maintain level at bottom of fill  
hole threads. See page 74.  
Front Prop Shaft  
Yoke  
Polaris Premium  
U-Joint Lube  
---  
Grease fittings (3 pumps  
maximum) every 500 miles,  
before long periods of stor-  
age, or after pressure wash-  
ing or submerging.  
Front Prop Shaft Yoke  
67  
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MAINTENANCE  
Engine Oil  
Oil Recommendations  
Polaris Premium 4 All Season synthetic engine oil has been specially  
formulated for use in Polaris 4-cycle engines. It's a fully synthetic, high  
performance, multi-viscosity oil designed to provide the ultimate in  
lubrication performance and protection. See page 117 for the part num-  
bers of Polaris products.  
Premium 4 possesses unsurpassed film strength over the widest possible  
temperature range. It resists viscosity and frictional breakdown in ambi-  
ent temperatures from -40° F. to 120° F. (-40° to +49° C.). Its excep-  
tional frictional properties result in more efficient operation, more  
power output and lower fuel consumption.  
Although Polaris Premium 4 is the only oil recommended for use in this  
engine, use of any API certified SH oil is allowable as long as it's 0W-  
40. Oil may need to be changed more frequently if Polaris Premium 4 is  
not used. Follow the manufacturer's recommendations for ambient tem-  
perature 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.  
68  
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MAINTENANCE  
Engine Oil  
Oil Level  
Access the oil dipstick and fill tube  
from the left side of the ATV.  
A rising oil level between checks in  
cool weather driving can indicate  
contaminants such as gas or mois-  
ture collecting in the crankcase. If  
the oil level is over the full/safe  
mark, change the oil immediately.  
Dipstick  
1. Position the vehicle on a level  
surface.  
2. Start the engine. Allow it to idle  
for 20-30 seconds. Stop the  
engine.  
Safe Range  
3. Remove the dipstick. Wipe it  
dry with a clean cloth.  
4. Reinstall the dipstick com-  
pletely.  
Safe  
Add Oil  
5. Remove the dipstick and check  
the oil level. Maintain the oil  
level in the safe range. Do not  
overfill.  
69  
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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 62. Always change the oil filter  
whenever changing oil.  
1. Position the vehicle on a level surface.  
2. Start the engine. Allow it to idle for two to three minutes.  
3. Stop the engine.  
4. Clean the area around the drain  
plug.  
5. Place a drain pan under the oil  
tank.  
Screen  
Fitting  
Drain  
Plug  
6. 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.  
New Sealing Washer  
7. Install a new sealing washer on  
the drain plug. The sealing sur-  
faces on drain plug and crank-  
case should be clean and free of  
burrs, nicks or scratches.  
8. Reinstall the drain plug. Torque  
to 14-17 ft. lbs. (19-23 Nm).  
9. Disconnect the lower oil deliv-  
ery hose and remove the screen  
fitting from the oil tank. Clean  
Alignment Mark  
the fitting. The fitting threads must be sealed with LOCTITE PST  
505 or PTFE seal tape.  
10. Reinstall the screen fitting and rotate the fitting clockwise a mini-  
mum of 2 1/2 turns into the tank threads. Continue to rotate the fit-  
ting until the nipple of the fitting aligns with the mark on the tank.  
Do not over-tighten. Maximum torque for the screen fitting is 25 ft.  
lbs. (34 Nm).  
11. Reattach the oil line.  
70  
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MAINTENANCE  
Oil and Filter Change  
12. Place shop towels beneath the oil  
filter. Using an oil filter wrench,  
turn the filter counter-clockwise  
to remove it.  
13. Using a clean dry cloth, clean the  
filter sealing surface on the crank-  
case.  
14. Lubricate the o-ring on the new  
filter with a film of fresh engine  
oil. Check to make sure the o-ring  
is in good condition.  
15. Install the new filter and rotate it clockwise by hand until the filter  
gasket contacts the sealing surface, then turn it an additional 1/2  
turn.  
16. 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. The sealing surfaces on the drain plug and crankcase should  
be clean and free of burrs, nicks or scratches.  
17. Reinstall the drain plug.Torque to 14 ft. lbs. (19 Nm).  
18. Remove the dipstick.  
19. Add two quarts (1.9 l) of recommended oil. Reinstall the dipstick.  
Tip: If the sump is not drained, add about 1 3/4 quarts (1.6 l) initially.  
20. Place the transmission in PARK.  
21. Lock the parking brake.  
22. Prime the oil pump using the procedure on page 72. Then stop  
the engine and inspect for leaks.  
23. Check the oil level. Add oil as needed to bring the level to the upper  
mark on the dipstick.  
24. Dispose of used filter and oil properly.  
71  
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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.  
Tank  
2"  
(5 cm)  
1. Clamp or pinch off the vent line  
approximately 2" (5 cm) from  
the oil tank, between the end of  
the oil tank vent fitting and the  
vent line's pressure relief slit.  
Clamp  
Pressure  
Relief Slit  
2. Start the engine. Allow it to idle  
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.  
Tip: If you do not hear air, the line has not bled. Repeat the priming procedure.  
72  
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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 62. Maintain the  
oil level at the bottom of the fill plug hole threads. We recommend the  
use of Polaris Premium AGL Synthetic Gearcase Lubricant. See page  
117 for the part numbers of Polaris products.  
The fill plug is located on the left side of the ATV, under the rear fender,  
behind the wheel.  
The drain plug is located on the right side of the gearcase, on the right  
side of the ATV, behind the wheel well.  
Fill Plug  
Drain Plug  
Oil Check  
1. Position the vehicle on a level  
Fill Plug  
surface.  
2. Remove the fill plug.  
3. Check the oil level.  
4. Reinstall the fill plug. Torque  
to 22 ft. lbs. (30 Nm).  
5. Reinstall the footwell.  
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MAINTENANCE  
Transmission Oil  
Oil Change  
1. Remove the fill plug.  
2. Place a drain pan under the  
gearcase.  
3. Remove the drain plug.  
Allow the oil to drain com-  
pletely.  
4. Clean and reinstall the drain  
plug. Torque to 22 ft. lbs.  
(30 Nm).  
Drain  
Plug  
5. Add 32 oz. (948 ml) of the recommended oil.  
6. Reinstall the fill plug. Torque to 22 ft. lbs. (30 Nm).  
7. Check for leaks. Dispose of used oil properly.  
Front Gearcase (Demand Drive) Fluid  
Always check and change the demand drive fluid at the intervals out-  
lined in the Periodic Maintenance Chart beginning on page 62. We rec-  
ommend the use of Demand Drive Plus Fluid. Use of other fluids may  
result in improper operation of components. See page 117 for the part  
numbers of Polaris products.  
Maintain the fluid level at  
the bottom of the fill hole  
threads. See below for  
capacity.  
Fill  
Plug  
The fill plug is located on  
the right side of the  
demand drive unit. The  
drain plug is located on the  
bottom right side of the  
unit.  
Drain Plug  
Fill Level  
Demand Drive Capacity  
Sportsman 500  
9 oz. (265 ml)  
74  
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MAINTENANCE  
Front Gearcase (Demand Drive) Fluid  
Fluid Check  
1. Position the vehicle on a level surface. Remove the fill plug. Check  
the fluid level.  
2. Add the recommended demand drive fluid as needed to bring the  
level to the bottom of the fill hole threads.  
3. Reinstall the fill plug. Torque to 8-10 ft. lbs. (11-14 Nm).  
Fluid Change  
1. Position the vehicle on a level surface. Remove the fill plug. Place a  
drain pan under the demand drive unit.  
2. Remove the drain plug. Allow the fluid to drain completely.  
3. Clean and reinstall the drain plug. Torque to 11 ft. lbs. (15 Nm).  
4. Add the recommended fluid. See page 74 for capacity. Maintain the  
fluid level at the bottom of the fill hole threads.  
5. Reinstall the fill plug. Torque to 8-10 ft. lbs. (11-14 Nm).  
6. Check for leaks. Dispose of used fluid properly.  
75  
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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 engine, past the pressure cap, and into  
the recovery bottle. As engine coolant temperature decreases the con-  
tracting (cooled) coolant is drawn back up from the bottle, past the pres-  
sure 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 117 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. Remove the left side panel.  
See page 80.  
2. Maintain the coolant level  
between the minimum and  
maximum marks on the bot-  
tle (when the fluid is cool).  
3. Add coolant as needed.  
76  
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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. Open the front box cover  
and pull open the access  
door.  
2. Remove the pressure cap.  
3. Using a funnel, slowly add  
coolant through the radia-  
tor filler neck.  
4. Reinstall the pressure cap.  
Use of a non-standard pres-  
sure cap will not allow the  
Radiator Cap  
recovery system to func-  
tion properly. Contact your  
dealer for the correct replacement part.  
5. Secure the access door.  
6. Secure the box cover.  
77  
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MAINTENANCE  
Brakes  
Hand Brake  
The front and rear brakes are hydraulic disc brakes, activated by moving  
the single brake lever toward the handlebar. These brakes are self-  
adjusting.  
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.  
WARNING! An over-full master cylinder may cause brake drag or brake lock-  
up, which could result in serious injury or death. Maintain brake fluid at the  
recommended level. Do not overfill.  
The following checks are recommended to keep the brake system in  
good operating condition. Check more often if brakes are used heavily  
under normal operation.  
1. Always keep brake fluid at an adequate  
level. See page 28.  
2. Check the brake system for fluid leaks.  
3. Check the brakes for excessive travel or  
spongy feel.  
4. Check the friction pads for wear, damage  
and looseness. Replace brake pads when  
they are worn to 3/64" (1 mm).  
3/64" (1 mm)  
5. Check the security and surface condition  
of the disc.  
Auxiliary Foot Brake  
The hydraulic auxiliary brake system requires no adjustment. Check the  
brake fluid level frequently for the auxiliary brake system. See page 30.  
78  
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MAINTENANCE  
Toe Alignment  
Use the following procedure to check the toe alignment of the vehicle.  
The recommended toe alignment is 1/8" to 1/4" (3-6 mm) toe out.  
WARNING! Severe injury or death can result from improper toe alignment and  
adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments  
should be performed by an authorized Polaris dealer.  
1. Position the vehicle on a  
level surface.  
2. Place the handlebars in a  
straight-ahead position.  
Stand  
String  
3. Tie a length of string  
between two stands as  
shown in the illustration.  
Position the stands so  
that the string is flush  
with the side of the rear  
tire. If available, you  
may use a long straight-  
edge instead of string.  
2
1
4. Measure the distance  
from the string to the  
rim at the front (1) and  
rear (2) of the front rim.  
The rear measurement  
should be 1/16"-1/8" (2-3 mm) more than the front measurement on  
each side of the vehicle to obtain the recommended 1/8" to 1/4" (3-6  
mm) toe out alignment.  
5. Repeat the measurement procedure on the other side of the vehicle.  
6. If you discover improper alignment, see your Polaris dealer for ser-  
vice.  
79  
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MAINTENANCE  
Steering Assembly  
The steering assembly of the ATV should be checked periodically for  
loose nuts and bolts. If loose nuts and bolts are found, see your Polaris  
dealer for service before operating the vehicle.  
Side Panel Removal  
1. Remove the seat.  
2. Grasp the rear of the side panel near the rear cab. With a firm  
motion, pull the panel outward to disengage the side panel from the  
grommet.  
3. Pull the panel downward and rearward to remove it.  
Step 1  
Step 2  
Step 3  
Footwell Removal  
1. Remove the four screws on  
Rivets  
the bottom of the footwell.  
2. Use a flat screwdriver or  
sidecutters to remove the  
plastic rivets securing the  
footwell to the fenders.  
3. Remove the footwell.  
Screws  
80  
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MAINTENANCE  
Tires  
WARNING  
Operating your ATV with worn tires, improperly inflated tires, non-standard tires  
or improperly installed tires will affect vehicle handling and could cause an  
accident resulting in serious injury or death. Always follow all tire maintenance  
procedures as outlined in this manual and on the labels on the vehicle. Always  
use original equipment size and type when replacing tires.  
Refer to the specifications section beginning on page 118 for recom-  
mended tire type, size and pressure.  
Tire Tread Depth  
Always replace tires  
when tread depth is  
worn to 1/8" (3 mm)  
or less.  
1/8" (3 mm)  
Front Wheel Hub Tightening  
Front wheel bearing tightness and spindle nut retention are critical com-  
ponent operations. All service must be performed by your authorized  
Polaris dealer.  
Wheel Removal  
1. Stop the engine.  
2. Place the transmission in PARK.  
3. Lock the parking brake.  
4. Loosen the wheel nuts slightly.  
WARNING! Do not service axle nuts that have a cotter pin installed. See your  
Polaris dealer.  
5. Elevate the side of the vehicle by placing a suitable stand under the  
footrest frame.  
6. Remove the wheel nuts.  
7. Remove the wheel.  
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MAINTENANCE  
Tires  
Wheel Installation  
1. Place the transmission in PARK.  
2. Lock the parking brake.  
3. Place the wheel on the hub with the valve stem toward the outside  
and rotation arrows on the tire pointing toward forward rotation.  
4. Install the wheel nuts and finger-tighten them.  
5. Lower the vehicle to the ground.  
6. Torque the wheel nuts to specification.  
WARNING! Loose nuts could cause a tire to come off during operation, which  
could result in an accident or overturn. Always ensure that all nuts are torqued to  
specification.  
90 ft. lbs.  
(122 Nm)  
27 ft. lbs.  
(37 Nm)  
Cast Aluminum  
Steel  
Wheel Nut Torque Specifications  
Check the wheel nut torques occasionally and when they've been loos-  
ened for maintenance service.  
Nut Type  
Nut Torque  
Lug Nut  
90 ft. lbs. (122 Nm)  
27 ft. lbs. (37 Nm)  
2-Piece Flange Nut  
82  
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MAINTENANCE  
Pre-Filter  
Air Filter  
1. Remove the seat.  
Main Filter  
2. Release the air box cover  
clips, and remove the air box  
cover.  
3. Loosen the clamp and  
remove the filter.  
4. Remove the fabric type pre-  
filter from the main filter.  
Wash the pre-filter in soapy  
water, then rinse and let dry.  
5. Reinstall the pre-filter over  
the main filter. Install a new  
main filter if needed.  
Breather  
Filter  
6. Reinstall the filter into the air  
box and tighten the clamp.  
Do not over-tighten the clamp, as filter damage could occur.  
7. Reinstall the air box cover and the seat.  
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MAINTENANCE  
Breather Filter/Hose  
The breather filter is on the hose that runs between the engine and air  
box. See illustration above.  
1. Remove the left side panel. See page 80.  
2. Remove the hose clamps from the filter and pull the filter out of the  
hoses.  
3. Inspect the filter for debris. Blow gently through the filter in the  
direction of the arrow to check for clogging. Replace a damaged or  
clogged filter.  
4. Check the hoses for cracks, deterioration, abrasion, or leaks.  
Replace as needed.  
5. Reinstall the filter and hose 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.  
84  
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MAINTENANCE  
Fuse Replacement  
If the engine stops or will not  
start, or if you experience  
other electrical failures, a fuse  
may need replacement.  
Locate and correct any short  
circuits that may have caused  
the blown fuse, then replace  
the fuse. Spare fuses are pro-  
vided in a compartment on  
the top of the access door.  
1. Open the front box cover.  
2. Open the access door.  
3. Remove the suspect fuse  
from the fuse panel. If the  
fuse is blown, install a  
new fuse with the same  
amperage.  
Fuses  
Fuse Panel  
5or6 15 20 20  
4. Secure the access door.  
5. Secure the box cover.  
85  
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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.  
Headlight Lamp 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 two screws on the lower front corners of the headlight  
pod.  
2. Remove the screw from the rear of the pod.  
3. Lift the pod slightly while depressing the tabs at the rear of the pod.  
4. Lift the pod cover and disconnect the speedometer harnesses from  
the speedometer.  
CAUTION! Hot components can cause burns to skin. Allow lamps to cool  
before servicing.  
5. Unplug the headlamp from the wiring harness. Be sure to pull on the  
connector, not on the wiring.  
6. Turn the lamp counter-clockwise to remove it.  
7. Apply dielectric grease to the socket and install the new lamp. Make  
sure the tab on the lamp locates properly in the housing.  
8. Reassemble the pod.  
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MAINTENANCE  
Lights  
High Beam Adjustment  
The headlight beam can be adjusted slightly upward or downward. Use  
the following procedure to make the adjustment.  
25 ft.  
(7.6 m)  
2" (5 cm)  
1. Position the vehicle on a level surface with the headlight approxi-  
mately 25 ft. (7.6 m) from a wall. Place the transmission in PARK.  
2. Measure the distance from the floor to the center of the headlight  
and make a mark on the wall at the same height.  
3. Start the engine.Turn the headlight switch to high beam.  
4. Observe the headlight aim on the wall. The most intense part of the  
headlight beam should be two inches (5 cm) below the mark on the  
wall. Include rider weight on the seat when measuring.  
5. The adjustment knob is located on the right side of the headlight  
pod. Adjust the beam to the desired position by turning the knob  
either clockwise or counter-clockwise.  
Low Beam Adjustment  
Phillips Screw  
The low beam can be adjusted slightly  
upward or downward.  
1. Loosen the phillips screw located  
at the rear of the headlamp.  
2. Tilt the headlamp upward or  
downward.  
3. Tighten the screw.  
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MAINTENANCE  
Lights  
Headlight Housing Replacement  
1. Remove the two screws on the lower front corners of the headlight  
pod.  
2. Lift the pod slightly while depressing the tabs at the rear of the pod.  
3. Lift the pod cover and disconnect the speedometer harnesses from  
the speedometer.  
4. Unplug the headlamp from the wiring harness.  
5. Use a small screwdriver to remove the o-rings from the headlight  
mounting tabs.  
6. Pull the headlight housing up to release it from the locking tabs.  
7. Lift the adjusting knob up to remove it from the locking tabs.  
8. Carefully pull the assembly up  
and out of the pod.  
9. Reverse the steps to install the  
new housing and reassemble  
the pod. The distance from the  
headlamp parting line to the  
end of the adjustment knob  
stop is 5 1/8" (13 cm).  
10. Adjust the headlight aim by  
5 1/8"  
turning the adjusting knob.  
(13 cm)  
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MAINTENANCE  
Lights  
Lower Headlamp Replacement  
1. Turn the back of the headlight  
harness counter-clockwise and  
pull the harness assembly away  
from the headlight assembly.  
2. Remove the headlamp and install  
the new headlamp.  
3. Reinstall the harness assembly  
into the headlight assembly.  
Harness  
4. Turn the headlight harness clock-  
wise to secure the headlamp.  
Taillight/Brakelight Lamp Replacement  
1. Remove the harness connector  
Connector  
from the back of the light  
assembly.  
2. Turn the lamp counter-clock-  
wise to remove it.  
3. Apply dielectric grease to the  
socket and install the new  
lamp.  
Lamp  
4. Reinstall the harness connector.  
5. Test the light for proper operation.  
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MAINTENANCE  
Spark Plugs  
Spark Plug Recommendations  
Refer to the specifications section beginning on page 118 for the recom-  
mended spark plug type and gap for your vehicle. Torque spark plugs to  
specification.  
NOTICE: Using non-recommended spark plugs can result in serious engine  
damage. Always use Polaris-recommended spark plugs.  
Plug Condition  
Torque Specification  
New Spark Plug  
9-11 ft. lbs. (12-15 Nm)  
17-20 ft. lbs. (23-27 Nm)  
Previously Installed Spark Plug  
Spark Plug Inspection  
Spark plug condition is indicative of engine operation. Check the spark  
plug firing end condition after the engine has been warmed up and the  
vehicle has been driven at higher speeds. Immediately check the spark  
plug for correct color. See page 91.  
CAUTION! A hot exhaust system and engine can cause burns. Wear  
protective gloves when removing a spark plug for inspection.  
1. Rotate the spark plug cap 1/4 turn and pull it off the spark plug.  
2. Using the special wrench provided in the tool pouch, rotate the  
spark plug counter-clockwise to remove it.  
3. Reverse the procedure for spark plug installation. Torque to specifi-  
cation.  
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MAINTENANCE  
Spark Plugs  
Spark Plug Inspection  
Normal Spark Plug  
The normal insulator tip is gray, tan or light brown. There will be few  
combustion deposits. The electrodes are not burned or eroded. This 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 your vehicle becomes immersed, major engine damage can result if  
the machine is not thoroughly inspected. Take the vehicle to your dealer  
before starting the engine. If it's impossible to take your ATV to a dealer  
before starting it, follow the steps outlined below.  
1. Move the ATV to dry land or at the very least, to water below the  
footrests.  
2. Check the air box. If water is present, dry the air box and replace the  
filter with a new filter.  
3. Turn the fuel valve off.  
4. Remove the spark plug.  
5. Loosen the carburetor drain  
screw.  
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.  
Drain Screw  
10. Attempt to start the engine. If  
necessary, repeat the drying pro-  
cedure.  
11. Take the ATV to your dealer for service as soon as possible, whether  
you succeed in starting it or not.  
12. If water has been ingested into the PVT, follow the procedure on  
page 96 for drying out the PVT.  
92  
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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. Remove the arrestor clean-out  
plug from the bottom of the  
muffler.  
Exhaust  
Outlet  
2. Place the transmission in  
PARK.  
3. Start the engine.  
4. Quickly squeeze and release  
the throttle lever several times  
to purge carbon from the system.  
Clean-Out Plug  
5. If carbon comes out of the exhaust, cover or plug the exhaust outlet.  
Wear protective gloves.  
6. Lightly tap on the exhaust pipe with a rubber mallet while repeating  
step 4.  
7. 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.  
8. Repeat steps 4 to 6 until no more particles are expelled.  
9. Stop the engine. Allow the arrestor to cool.  
10. 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.  
94  
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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.  
On Polaris ATVs, the approximate gear ratio difference between high  
and low range is 1:2.25. This difference in gearing affects the operation  
of the PVT, especially at speeds less than 7 MPH (11 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) in  
low range, the engine speed would be around 3000 RPM. This is well  
above the engagement speed of 1200 - 1400 RPM. However, in high  
range at 3 MPH (5 km/h), the engine would be running at only 1500  
RPM. Whenever operating this close to the engagement 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.  
The air temperature in the clutch cover is substantially reduced by using  
low range while operating at low ground speeds. Reducing the tempera-  
ture inside the clutch cover greatly extends the life of the PVT compo-  
nents (belt, cover, etc.).  
95  
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MAINTENANCE  
PVT System  
When To Use Low Range and High Range  
Condition  
Range to Use  
Operating at speeds less than 7 MPH (11 km/h)  
Towing heavy loads  
Low  
Low  
Low  
High  
Operating in rough terrain (swamps, mountains, etc.)  
Operating at speeds greater than 7 MPH (11 km/h)  
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. Position the vehicle on a level surface.  
2. Remove the drain plug. Allow the water to drain completely. Rein-  
stall the drain plug.  
3. Start the engine. Place the transmission in PARK.  
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 to the lowest available range.  
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.  
96  
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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 ATV may have either a sealed battery, which requires little mainte-  
nance, or a conventional battery. A sealed battery can be identified by its  
flat covers on the top of the battery. A conventional battery has six filler  
caps on the top of the battery.  
Always keep battery terminals and connections free of corrosion. If  
cleaning is necessary, remove corrosion with a stiff wire brush. Wash  
with a solution of one tablespoon baking soda and one cup water. Rinse  
well with tap water and dry off with clean shop towels. Coat the termi-  
nals with dielectric grease or petroleum jelly. Be careful not to allow  
cleaning solution or tap water into a conventional battery.  
97  
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MAINTENANCE  
Battery  
Battery Removal  
1. Disconnect the battery hold-down strap.  
2. Remove the battery cover.  
3. On conventional batteries, remove the battery vent tube.  
4. Disconnect the black (negative) battery cable first.  
5. Disconnect the red (positive) battery cable last.  
6. Lift the battery out of the ATV. Be careful not to tip a conventional  
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.  
98  
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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 101 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.  
99  
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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 117 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.  
100  
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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 98.  
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 99. 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 guidelines on the next page for recharging.  
101  
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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  
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  
102  
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MAINTENANCE  
Camber and Caster  
The camber and caster are non-adjustable.  
Rear Spring  
The rear shock absorber spring is adjusted  
by rotating the adjuster either clockwise  
or counter-clockwise to increase or  
decrease spring tension.  
Adjuster  
Accessory springs are available through  
your Polaris dealer.  
Handlebars  
The handlebars can be adjusted for rider  
preference.  
WARNING! Improper adjustment of the handlebars or incorrect torquing of the  
adjuster block tightening bolts can cause limited steering or loosening of the  
handlebars, resulting in loss of control and serious injury or death. Follow the  
adjustment procedures exactly, or see your Polaris dealer for service.  
1. Remove the upper headlight  
pod.  
2. Loosen the four handlebar  
bolts.  
3. Adjust the handlebar to the  
desired height.  
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  
Handlebar  
Bolts  
10-12 ft. lbs. (14-17 Nm), then  
torque the rear two bolts. A  
gap of up to 1/8" (3 mm) will  
remain at the rear of the clamp  
blocks.  
103  
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MAINTENANCE  
Carburetor  
Your Polaris ATV is calibrated at the factory for optimal performance at  
altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of  
+40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the  
engine air/fuel mixture becomes overly rich and the engine loses  
approximately 3% of its power for each 1000-foot (304.8 m) increase in  
elevation. Although this power cannot be regained, adjustments to the  
carburetor and drive system can be made to allow more efficient opera-  
tion. Optional jets, available from your Polaris dealer, are required for  
operation above 6,000 feet and temperatures below +40 degrees F. (4  
degrees C.)  
Continuous operation of the engine without proper jetting when  
required can cause poor performance, overheating or PVT or engine  
damage. See your Polaris dealer for more information about jetting the  
ATV for conditions in your area.  
Pilot screws are sealed with metal plugs and are serviceable only by  
Polaris dealers.  
Carburetor/Engine Idle RPM Adjustment  
Recommended engine idle RPM is 1200 +/- 200. If the engine idle  
speed is unsatisfactory and all other conditions are favorable, the carbu-  
retor can be adjusted.  
1. Start the engine and allow it to  
warm up for approximately five  
minutes.  
2. Place the transmission in gear.  
3. Lock the parking brake.  
4. Turn the screw in (clockwise) to  
raise RPM. Turn the screw out  
(counter-clockwise) to lower  
RPM.  
Idle Screw  
104  
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MAINTENANCE  
Throttle Cable Freeplay  
Adjust throttle cable freeplay at the handlebar.  
1. Locate the throttle cable  
adjuster at the handlebar.  
2. Squeeze the end of the rub-  
ber boot and slide it far  
enough to expose the end of  
the inline cable adjuster.  
3. Loosen the adjuster lock nut.  
4. Rotate the boot to turn the  
adjuster until 1/16" to 1/8"  
(1.5-3 mm) of freeplay is  
achieved at the thumb lever.  
While adjusting freeplay, be  
sure to flip the throttle lever  
back and forth.  
Boot  
5. Tighten the lock nut.  
6. Squeeze the end of the rub-  
ber boot and slide it over the  
cable adjuster to its original  
position.  
Lock Nut  
Adjuster  
105  
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MAINTENANCE  
Cleaning and Storage  
Washing the Vehicle  
Keeping your Polaris vehicle clean will not only improve its appearance  
but it can also extend the life of various components.  
NOTICE: High water pressure may damage components. Polaris recommends  
washing the vehicle by hand or with a garden hose, using mild soap.  
Certain products, including insect repellents and chemicals, will  
damage plastic surfaces. Do not allow these types of products to  
contact the vehicle.  
The best and safest way to clean your Polaris vehicle is with a garden  
hose and a pail of mild soap and water.  
1. Use a professional-type washing cloth, cleaning the upper body first  
and the lower parts last.  
2. Rinse with clean water frequently.  
3. Dry surfaces with a chamois to prevent water spots.  
Washing Tips  
• Avoid the use of harsh cleaners, which can scratch the finish.  
• Do not use a power washer to clean the vehicle.  
• Do not use medium to heavy duty compounds on the finish.  
• Always use clean cloths and pads for cleaning and polishing. Old or  
reused cloths and pads may contain dirt particles that will scratch the  
finish.  
106  
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MAINTENANCE  
Cleaning and Storage  
Washing the Vehicle  
If a high pressure water system is used for cleaning (not recommended),  
exercise extreme caution. The water may damage components and could  
remove paint and decals. Avoid directing the water stream at the follow-  
ing items:  
• Wheel bearings  
• Radiator  
• Transmission seals  
• Brakes  
• Cab and body panels  
• Electrical components  
• Switches and controls  
• 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.  
107  
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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.  
108  
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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 106.  
Stabilize the Fuel  
1. Fill the fuel tank.  
2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer.  
Follow the instructions on the container for the recommended  
amount. Carbon Clean removes water from fuel systems, stabilizes  
fuel and removes carbon deposits from pistons, rings, valves and  
exhaust systems.  
3. Allow the engine to run for 15-20 minutes to allow the stabilizer to  
disperse through the fuel in the tank and carburetor.  
4. Turn the fuel valve off.  
5. Drain the carburetor bowl.  
Oil and Filter  
Change the oil and filter. See page 70.  
Air Filter / Air Box  
1. Inspect and clean (or replace) the pre-cleaner and air filter. See page  
83.  
2. Clean the air box.  
3. Drain the sediment tube.  
4. Clean or replace the breather filter. See page 84.  
109  
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MAINTENANCE  
Cleaning and Storage  
Storage Tips  
Fluid Levels  
Inspect the fluid levels. Add or change fluids as recommended in the  
Periodic Maintenance Chart beginning on page 62.  
• Demand drive unit (front gearcase)  
• Rear gearcase (if equipped)  
• Transmission  
• Brake fluid (change every two years and any time the fluid looks dark  
or contaminated)  
• Coolant (test strength/fill)  
Fog the Engine  
1. Support the front end of the machine so the engine is level or tilted  
slightly rearward.  
2. Remove the spark plug. Rotate the piston to BDC and pour two  
ounces (59 ml) of Premium 4 Synthetic 0W40 engine oil into the  
cylinder.  
3. Reinstall the spark plug. Torque to specification.  
4. Apply dielectric grease to the inside of the spark plug cap. Reinstall  
the cap.  
5. Turn the engine over several times using the recoil starter. Oil will  
be forced in and around the piston rings and ring lands, coating the  
cylinder with a protective film of fresh oil.  
6. Treat the fuel system with Polaris Carbon Clean. See page 109.  
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.  
110  
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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 62.  
Battery Storage  
See pages 100-101 for storage and charging procedures.  
Storage Area/Covers  
Set the tire pressure and safely support the ATV with the tires slightly  
off the ground. Be sure the storage area is well ventilated. Cover the  
vehicle with a genuine Polaris cover. Do not use plastic or coated mate-  
rials. They do not allow enough ventilation to prevent condensation, and  
may promote corrosion and oxidation.  
Accessories  
Auxiliary power outlets provide 12-volt power for operating accesso-  
ries. Accessory outlets are available for all models. Polaris also has a  
wide range of additional accessories available for your ATV. Always  
install accessories that are approved for ATV use. Please see your  
Polaris dealer.  
111  
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MAINTENANCE  
Transporting the ATV  
Follow these procedures when  
transporting the vehicle.  
1. Stop the engine.  
2. Place the transmission in  
PARK.  
3. Lock the parking brake.  
4. Secure the fuel cap, oil cap  
and seat.  
5. Always tie the frame of the  
ATV to the transporting  
unit securely with suitable  
straps or rope. Do not  
attach tie straps to the front  
A-arm bolt pockets, racks  
or handlebars.  
6. Remove the key to prevent  
loss during transporting.  
112  
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TROUBLESHOOTING  
Drive Belt Wear/Burn  
Possible Cause  
Solution  
Driving onto a pickup or Use low range during loading.  
tall trailer in high range  
Starting out going up a  
steep incline  
Use low range or turn around using the K-turn (see page  
54).  
Driving at low RPM or  
Drive at a higher speed or use low range more frequently.  
ground speed (3-7 MPH) See page 96.  
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.  
Utility use/plowing  
Use low range only.  
Stuck in mud or snow  
Shift the transmission to low range and carefully use fast,  
aggressive throttle application to engage clutch.  
WARNING! Excessive throttle may cause loss of control  
and vehicle overturn.  
Climbing over large  
objects from a stopped  
position  
Shift the transmission to low range and carefully use fast,  
brief, aggressive throttle application to engage clutch.  
WARNING! Excessive throttle may cause loss of control  
and vehicle overturn.  
Belt slippage from water Dry out the PVT. See page 96. 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 or  
fuel lines. See your dealer.  
Slippage from failure to  
warm up belt  
Always warm up the belt by operating below 30 mph for  
one mile (5 miles or more when temperature is below  
freezing).  
Wrong or missing belt  
Improper break-in  
Install the recommended belt.  
Always break in a new belt and/or clutch. See page 42.  
113  
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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  
Check all connections and tighten  
Loose battery connections  
Loose solenoid connections  
Engine Turns Over, Fails to Start  
Possible Cause  
Solution  
Out of fuel  
Refuel  
Clogged fuel valve or filter  
Water is present in fuel  
Old or non-recommended fuel  
Fuel valve is turned off  
Fouled or defective spark plug(s)  
No spark to spark plug  
Water or fuel in crankcase  
Overuse of choke  
Inspect and clean or replace  
Drain the fuel system and refuel  
Replace with fresh recommended fuel  
Turn the fuel valve on  
Inspect plugs and replace if necessary  
Inspect plugs, verify stop switch is on  
Immediately see your Polaris dealer  
Inspect, clean and/or replace spark plugs  
Recharge the battery to 12.8 VDC  
See your dealer  
Low battery voltage  
Mechanical failure  
Engine Backfires  
Possible Cause  
Solution  
Weak spark from spark plug  
Incorrect spark plug gap or heat range  
Old or non-recommended fuel  
Incorrectly installed spark plug wires  
Incorrect ignition timing  
Inspect, clean and/or replace spark plugs  
Set gap to specs or replace plugs  
Replace with fresh recommended fuel  
See your dealer  
See your dealer  
Mechanical failure  
See your dealer  
Loose ignition connections  
Water present in fuel  
Check all connections and tighten  
Replace with fresh recommended fuel  
114  
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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  
Set gap to specs or replace plugs  
Engine Runs Irregularly, Stalls or Misfires  
Possible Cause  
Solution  
Fouled or defective spark plug(s)  
Inspect, clean and/or replace spark  
plug(s)  
Worn or defective spark plug wires  
Incorrect spark plug gap or heat range  
Loose ignition connections  
Water present in fuel  
See your dealer  
Set gap to specs or replace plugs  
Check all connections and tighten  
Replace with new fuel  
Recharge battery to 12.8 VDC  
Inspect and replace  
Low battery voltage  
Kinked or plugged fuel tank vent line  
Incorrect fuel  
Replace with recommended fuel  
Inspect and clean or replace  
See your dealer  
Clogged air filter  
Reverse speed limiter malfunction  
Electronic throttle control malfunction  
Other mechanical failure  
See your dealer  
See your dealer  
Possible Lean Fuel Cause  
Solution  
Low or contaminated fuel  
Kinked or plugged fuel tank vent line  
Low octane fuel  
Add or change fuel, clean the fuel system  
Inspect and replace  
Replace with recommended fuel  
Replace filter  
Clogged fuel filter  
Incorrect fuel  
Replace with recommended fuel  
See your Polaris dealer  
Incorrect jetting  
Possible Rich Fuel Cause  
Solution  
Fuel is very high octane  
Overuse of choke  
Replace with lower octane fuel  
Inspect, clean and/or replace spark plugs  
Stopping/starting without adequate  
warm-up  
Allow engine to warm up before operat-  
ing and/or stopping  
Incorrect fuel  
Replace with recommended fuel  
Inspect and clean or replace  
See your Polaris dealer  
Clogged air filter  
Incorrect jetting  
115  
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TROUBLESHOOTING  
Engine Stops or Loses Power  
Possible Cause  
Solution  
Out of fuel  
Refuel, cycle key to ON position three  
times for 5 seconds each, then start  
Kinked or plugged fuel vent line  
Overuse of choke  
Inspect and replace  
Inspect, clean and/or replace spark plugs  
Replace with new fuel  
Water is present in fuel  
Fouled or defective spark plug(s)  
Inspect, clean and/or replace spark  
plug(s)  
Worn or defective spark plug wires  
Incorrect spark plug gap or heat range  
Loose ignition connections  
Low battery voltage  
See your dealer  
Set gap to specs or replace plug  
Check all connections and tighten  
Recharge the battery to 12.8 VDC  
Replace with fresh recommended fuel  
Inspect and clean or replace  
See your dealer  
Incorrect fuel  
Clogged air filter  
Reverse speed limiter malfunction  
Electronic throttle control malfunction  
Other mechanical failure  
Overheated engine  
See your dealer  
See your dealer  
Clean radiator screen and core, clean  
engine exterior, see your dealer  
Engine Overheating  
Possible Cause  
Solution  
Debris lodged in screen  
Remove and clean the screen. Pull on the  
top portion of the screen, then remove the  
lower portion.  
Plugged Radiator  
Use a garden hose to flush any debris  
from the radiator fins. NOTE: High pres-  
sure washers can deform the radiator fins  
and reduce cooling efficiency.  
Obstructed cooling fan  
Clean any debris or mud that may be  
interfering with fan movement.  
116  
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POLARIS PRODUCTS  
Part  
Number  
Description  
Engine Lubricant  
Fogging Oil (12 oz. Aerosol)  
2870791  
2871281  
2871844  
Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt./.95 l)  
Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (gal./3.8 l)  
Gearcase / Transmission Lubricants  
Premium AGL Synthetic Gearcase Lubricant (qt./.95 l)  
Premium AGL Synthetic Gearcase Lube (gal./3.8 l)  
Demand Drive Plus Fluid (qt./.95 l)  
Demand Drive Plus Fluid (gal./3.8 l)  
Pump for Gallon (3.8 l) Jug  
Premium Demand Drive Hub Fluid (237 ml)  
Premium Demand Drive Hub Fluid (9.5 l)  
Coolant  
2873602  
2873603  
2877922  
2877923  
2870465  
2871654  
2872277  
2871323  
2871534  
60/40 Coolant (gal./3.8 l)  
60/40 Coolant (qt./.95 l)  
Grease / Specialized Lubricants  
2871312  
2871322  
2871423  
2871460  
2871515  
2871551  
2871329  
2872073  
2872348  
Grease Gun Kit, Premium All Season  
Premium All Season Grease (3 oz./89 ml cartridge)  
Premium All Season Grease (14 oz./414 ml cartridge)  
Starter Drive Grease  
Premium U-Joint Lube (3 oz./89 ml cartridge)  
Premium U-Joint Lube (14 oz./414 ml cartridge)  
Dielectric Grease (NyogelTM  
)
Chain Lube, Aerosol (6.25 oz./185 ml)  
Chain Lube, Aerosol (16 oz./473 ml)  
Additives / Miscellaneous  
Carbon Clean Plus  
Fuel Stabilizer  
DOT 4 Brake Fluid  
2871326  
2870652  
2872189  
2871956  
2859044  
LoctiteTM 565 Thread Sealant  
Polaris Battery TenderTM Charger  
117  
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SPECIFICATIONS  
Sportsman 500  
Gross Vehicle Weight  
Maximum Weight Capacity  
Dry Weight  
1200 lbs. (544 kg)  
485 lbs. (220 kg) (operator, cargo, accessories)  
696 lbs. (316 kg)  
Fuel Capacity  
4.25 gal. (16 l)  
Engine Oil Capacity  
Transmission Oil Capacity  
Demand Drive Fluid Capacity  
Coolant Capacity  
2 qts. (1.9 l)  
32 oz. (948 ml)  
9 oz. (265 ml)  
2.7 qts. (2.5 l)  
Front Rack/Storage Box Capacity 90 lbs. (40.8 kg)  
Rear Rack/Storage Box Capacity 180 lbs. (81.6 kg)  
Receiver Hitch Tongue Capacity 120 lbs. (54 kg) (Rear rack capacity and tongue  
weight not to exceed 180 lbs./81.6 kg)  
Hitch Towing Rating  
Unbraked Trailer Towing  
Capacity*  
1225 lbs. (555.7 kg)  
1786 lbs. (810 kg)  
Overall Length  
Overall Width  
Overall Height  
Wheelbase  
Ground Clearance  
Minimum Turning Radius  
Engine  
83 in. (211 cm)  
48 in. (122 cm)  
48 in. (122 cm)  
50.5 in. (128.3 cm)  
11 in. (28 cm)  
65 in. (165 cm) unloaded  
EH500PLE  
Displacement  
Bore x Stroke  
Alternator Output  
Compression Ratio  
Carburetor  
498 cc  
92 x 75  
260 w  
10.2:1  
40mm Mikuni  
40  
Pilot Jet  
Main Jet  
155  
Needle Jet  
X-6M  
Jet Needle  
6MGHI 194  
Pilot Screw  
By flow (taper 12.5°) (Brass Plug)  
Digital CDI  
30° +/- 2° @ 5000 RPM  
NGK BKR6E / .035 in. (0.9 mm)  
Dry Sump  
Ignition System  
Ignition Timing  
Spark Plug / Gap  
Lubrication System  
* Based on EU Directive 76/432/EC  
118  
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SPECIFICATIONS  
Sportsman 500  
Driving System Type  
Front Suspension  
Rear Suspension  
Shift Type  
Automatic PVT (Polaris Variable Transmission)  
MacPherson strut with 8.2" (21 cm) travel  
Progressive rate with 9.5" (24 cm) travel  
Side Lever (H/L/N/R/P)  
23.91:1  
Gear Reduction, Low  
Gear Reduction, Reverse  
Gear Reduction, Forward  
Drive Ratio, Front  
Tires/Pressure, Front  
Tires/Pressure, Rear  
Brakes, Front  
16.30:1  
10.49:1  
3.82:1  
25x8-12 / 5 psi  
25x11-12 / 5 psi  
Single-Control Hydraulic Disc  
Single-Control Hydraulic Disc  
Foot-Activated Hydraulic Disc  
Hydraulic lock, all wheel  
Brakes, Rear  
Brake, Auxiliary  
Brake, Parking  
Headlight  
1 Single Beam on Headlight Pod (50 watt)  
2 Single Beam on Bumper (37.5 watt)  
Taillights  
8.26 watts  
26.9 watts  
LCD  
Brake Light  
Instrument Cluster  
Jetting Chart  
AMBIENT TEMPERATURE  
ALTITUDE  
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  
Weight  
Drive Clutch  
Driven  
Clutch  
Spring  
Helix and  
Spring  
Setting  
Spring  
Meters  
(Feet)  
0-1800  
(0-6000)  
10 WH  
Blue/Green  
Black  
PN 7041782  
41-37°  
PN 5132344  
2+2  
PN 5630710 PN 7041157  
1800-3700  
10 RH  
Blue/Green  
Black  
PN 7041782  
41-37°  
PN 5132344  
2+2  
(6000-12000) PN 5630709 PN 7041157  
119  
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DECLARATION OF CONFORMITY  
Polaris Industries Inc.,  
2100 Hwy 55, Medina, MN 55340 U.S.A.  
Telephone 763-542-0500  
We, Polaris Industries Inc., declare that the vehicles listed below conform to the  
essential health and safety requirements applicable to off-road all-terrain vehicles.  
APPLICABLE EUROPEAN DIRECTIVES  
TEST / EVALUATION METHODS  
98/37/EC as amended (Machinery Directive)  
EN 1050 hazard analysis  
CD 77/311/EEC driver-perceived noise level  
2004/108/EC as amended (EMC Directive)  
CISPR 12:2001  
CAN/CSA-C108.4-M92  
EN 55012:2002  
EN 61000-6-2:2001  
PRODUCT IDENTIFICATION  
VEHICLE SERIES  
TRADE NAME  
MODEL  
YEARS  
SOUND  
PRESSURE  
dB (A)  
___KA05__  
___KA09__  
___FA09__  
___VA17__  
___PB20__  
___BA32__  
___CA32__  
___BA50__  
___GJ45__  
___GJ52__, ___GP52__  
___LH27__  
___LH46__  
___MN50__  
OUTLAW 50  
OUTLAW 90  
SPORTSMAN 90  
RZR 170  
PHOENIX 200  
TRAIL BLAZER 330  
TRAIL BOSS 330  
SCRAMBLER 500  
OUTLAW 450  
2008, 2009, 2010  
2008, 2009, 2010  
2008, 2009, 2010  
2009, 2010  
76.8  
76.8  
76.8  
81.3  
76.8  
76.8  
76.8  
79.6  
80.7  
80.7  
81.1  
80.2  
80.4  
80.8  
77.2  
83.6  
77.2  
80.1  
80.4  
76.5  
76.5  
76.5  
76.5  
76.5  
85.8  
2008, 2009, 2010  
2008, 2009, 2010  
2008, 2009, 2010  
2008, 2009, 2010  
2008, 2009, 2010  
2008, 2009, 2010  
2008, 2009, 2010  
2008, 2009, 2010  
2008, 2009, 2010  
2009, 2010  
OUTLAW 525  
SPORTSMAN 300  
SPORTSMAN 400  
SPORTSMAN 500 EFI  
SPORTSMAN 550 EFI  
___ZN55__ ___ZX55__  
___TN55__, ___DN55__ SPORTSMAN X2/TOURING 550 2010  
___MN76__ SPORTSMAN 800 2008, 2009, 2010  
___TN85__, ___DN85__ SPORTSMAN X2/TOURING 850 2010  
___CL76__  
___ZN85__, ___ZX85__  
SPORTSMAN 800 6X6  
SPORTSMAN 850 EFI  
2009, 2010  
2009, 2010  
2009, 2010  
2010  
2010  
2010  
___RH50__, ___HH50__ RANGER 500 EFI 4X4  
___HH76__  
___WH76__  
___HR__  
___HY__  
___VH76__  
RANGER 800 EFI 4X4  
RANGER 800 EFI CREW  
RANGER 800 6X6  
RANGER HD 800 4X4  
RANGER RZR  
2010  
2008, 2009, 2010  
Authorized Signatory:  
_________  
Alexander A. Kennedy, Product Compliance  
Polaris Industries Inc., Engineering Operations  
301 5th Avenue SW, Roseau, MN 56751  
120  
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WARRANTY  
LIMITED WARRANTY  
Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM-  
ITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against  
defects in material or workmanship. Polaris also gives a one year limited warranty on  
the final drive chain for failure due to defects. This warranty covers the parts and labor  
charges for repair or replacement of defective parts which are covered by this warranty.  
This warranty begins on the date of purchase. This warranty is transferable to another  
consumer during the warranty period through a Polaris dealer.  
REGISTRATION  
At the time of sale, the Warranty Registration Form must be completed by your dealer  
and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will  
record the registration for warranty. No verification of registration will be sent to the  
purchaser as the copy of the Warranty Registration Form will be the warranty entitle-  
ment. If you have not signed the original registration and received the customer copy,  
please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE  
ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS.  
Initial dealer preparation and set-up of your ATV is very important in ensuring trouble-  
free operation. Purchasing a machine in the crate or without proper dealer set-up will  
void your warranty coverage.  
121  
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WARRANTY  
WARRANTY COVERAGE AND EXCLUSIONS:  
LIMITATIONS OF WARRANTIES AND REMEDIES  
The Polaris limited warranty excludes any failures that are not caused by a defect in  
material or workmanship. This warranty does not cover accidental damage, normal wear  
and tear, abuse or improper handling. This warranty also does not cover any ATV that  
has been altered structurally, modified, neglected, improperly maintained, used for rac-  
ing, or used for purposes other than for which it was manufactured, or for any damages  
which occur during trailer transit or as a result of unauthorized service or the use of  
unauthorized parts. In addition, this warranty does not cover physical damage to paint or  
finish, stress cracks, tearing or puncturing of upholstery material, corrosion, or defects in  
parts, components or the ATV due to fire, explosions or any other cause beyond Polaris'  
control.  
Warranty does not apply to parts exposed to friction surfaces, stresses, environmental  
conditions and/or contamination for which they were not designed or not intended,  
including but not limited to the following items:  
Wheels and tires  
Finished and unfinished surfaces  
Carburetor/Throttle body components  
Engine components  
Suspension components  
Brake components  
Seat components  
Clutches and components  
Steering components  
Batteries  
Drive belts  
Hydraulic components  
Circuit breakers/Fuses  
Electronic components  
Light bulbs/Sealed beam lamps  
Warranty applies to the product only and does not allow for coverage of personal loss.  
Some items are considered "consumable," meaning they are considered part of normal  
maintenance or part of completing an effective repair. The following items are excluded  
from warranty coverage in the event of a warranty claim:  
Spark Plugs  
Filters  
Fuel  
Sealants  
Hotel fees  
Towing charges  
Mileage  
Rentals/Loss of product use  
Lubricants such as oil, grease, etc.  
Batteries (unless defective)  
Cosmetic damage/repair  
Coolants  
Meals  
Shipping/ handling fees  
Product pick-up/delivery  
Loss of vacation/personal time  
122  
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WARRANTY  
LIMITATIONS OF WARRANTIES AND REMEDIES  
This warranty also excludes failures resulting from improper lubrication; improper  
engine timing; improper fuel; surface imperfections caused by external stress, heat, cold  
or contamination; operator error or abuse; improper component alignment, tension,  
adjustment or altitude compensation; failure due to snow, water, dirt or other foreign  
substance ingestion/contamination; improper maintenance; modified components; use  
of aftermarket components resulting in failure; unauthorized repairs; repairs made after  
the warranty period expires or by an unauthorized repair center; use of the product in  
competition or for commercial purposes. Warranty will not apply to any product which  
has been damaged by abuse, accident, fire or any other casualty not determined a defect  
of materials or workmanship.  
This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that  
are not compatible with the ATV. The exclusive remedy for breach of this warranty shall  
be, at Polaris' exclusive option, repair or replacement of any defective materials, or com-  
ponents or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE  
ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR-  
RANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI-  
DENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION,  
WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY  
OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. Some  
states do not permit the exclusion or limitation of incidental or consequential damages  
or implied warranties, so the above limitations or exclusions may not apply to you if  
inconsistent with controlling state law.  
123  
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WARRANTY  
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE  
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-  
TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX  
MONTH 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 ATV requires warranty service, you must take it to a Polaris dealer authorized to  
repair Polaris ATVs. When requesting warranty service you must present your copy of  
the Warranty Registration form to the dealer. (THE COST OF TRANSPORTATION TO  
AND FROM THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests that you  
use your original selling dealer; however, you may use any Polaris Servicing Dealer to  
perform warranty service.  
Please work with your dealer to resolve any warranty issues. Should your dealer require  
any additional assistance they will contact the appropriate person at Polaris.  
This warranty gives you specific legal rights, and you may also have other rights which  
vary from state to state.  
If any of the above terms are void because of state or federal law, all other warranty  
terms will remain in effect.  
Engine Oil  
1. Mixing oil brands or using non-recommended oil may cause engine damage. We rec-  
ommend the use of Polaris engine oil for your ATV.  
2. Damage resulting from the use of non-recommended lubricants may not be covered  
by warranty.  
SPARK ARRESTOR  
Polaris warrants that the spark arrestor in this vehicle will meet the efficiency require-  
ments of USFS standard 5100-1c for at least 1000 hours when subjected to normal use  
and when maintenance and installation are in accordance with Polaris recommendations.  
124  
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WARRANTY  
Exported Vehicles  
EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-  
RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD  
OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCA-  
TION.  
This policy does not apply to vehicles that have received authorization for export from  
Polaris Industries. Dealers may not give authorization for export. You should consult an  
authorized dealer to determine this vehicle's warranty or service bulletin coverage if you  
have any questions.  
This policy does not apply to vehicles registered to government officials or military per-  
sonnel on assignment outside the country of the selling dealer's authorized location.  
This policy does not apply to Safety Recalls.  
How to Get Service  
In the Country where your vehicle was purchased:  
Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you  
move or are traveling within the country where your vehicle was purchased, Warranty or  
Service Bulletin repairs may be requested from any authorized Polaris dealer who sells  
the same line as your vehicle.  
Outside the Country where your vehicle was purchased:  
If you are traveling temporarily outside the country where your vehicle was purchased,  
you should take your vehicle to an authorized Polaris dealer. You must show the dealer  
photo identification from the country of the selling dealer's authorized location as proof  
of residence. Upon residence verification, the servicing dealer will be authorized to per-  
form the warranty repair.  
If You Move:  
If you move to another country, be sure to contact Polaris Customer Assistance and the  
customs department of the destination country before you move. Vehicles importation  
rules vary considerably from country to country. You may be required to present docu-  
mentation of your move to Polaris Industries in order to continue your warranty cover-  
age. You may also be required to obtain documentation from Polaris Industries in order  
to register your vehicle in your new country.  
125  
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WARRANTY  
Exported Vehicles  
How to Get Service  
If Purchased From A Private Party:  
If you purchase a Polaris product from a private citizen, to be kept and used outside of  
the country in which the vehicle was originally purchased, all warranty coverage will be  
denied.  
Notice  
If your vehicle is registered outside of the country where it was purchased, and you have  
not followed the procedure set out above, your vehicle will no longer be eligible for war-  
ranty or service bulletin coverage of any kind. (Vehicles registered to Government offi-  
cials or military personnel on assignment outside of the country where the vehicle was  
purchased will continue to be covered by the basic warranty.)  
For questions call Polaris Customer Assistance:  
United States: 1-888-704-5290  
Canada: 1-204-925-7100  
126  
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WARRANTY  
U.S.A. EPA Emissions Limited Warranty  
This emissions limited warranty is in addition to the Polaris standard limited warranty  
for your vehicle. Polaris Industries Inc. warrants that at the time it is first purchased, this  
emissions-certified vehicle is designed, built and equipped so it conforms with applica-  
ble U.S. Environmental Protection Agency emission regulations. Polaris warrants that  
the vehicle is free from defects in materials and workmanship that would cause it to fail  
to meet these regulations.  
The warranty period for this emissions-certified vehicle starts on the date the vehicle is  
first purchased and continues for a period of 500 hours of engine operation, 5000 kilo-  
meters (3100 miles) of vehicle travel, or 30 calendar months from the date of purchase,  
whichever comes first.  
This emissions limited warranty covers components whose failure increases the vehi-  
cle’s regulated emissions, and it covers components of systems whose only purpose is to  
control emissions. Repairing or replacing other components not covered by this war-  
ranty is the responsibility of the vehicle owner. This emissions limited warranty does not  
cover components whose failure does not increase the vehicle’s regulated emissions.  
For exhaust emissions, emission-related components include any engine parts related to  
the following systems:  
Air-induction system  
Fuel system  
Ignition system  
Exhaust gas recirculation systems  
The following parts are also considered emission-related components for exhaust emis-  
sions:  
Aftertreatment devices  
Crankcase ventilation valves  
Sensors  
Electronic control units  
The following parts are considered emission-related components for evaporative emis-  
sions:  
Fuel Tank  
Fuel Cap  
Fuel Line  
Fuel Line Fittings  
Clamps*  
Pressure Relief Valves*  
Control Valves*  
Control Solenoids*  
Electronic Controls*  
Vacuum Control Diaphragms*  
Control Cables*  
Control Linkages*  
Purge Valves  
Vapor Hoses  
Liquid/Vapor Separator  
Carbon Canister  
Canister Mounting Brackets  
Carburetor Purge Port Connector  
*As related to the evaporative emission control system.  
127  
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WARRANTY  
U.S.A. EPA Emissions Limited Warranty  
The exclusive remedy for breach of this limited warranty shall be, at the exclusive  
option of Polaris, repair or replacement of any defective materials, components or prod-  
ucts. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE  
ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR-  
RANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI-  
DENTAL, 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.  
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY  
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-  
TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY  
PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS WARRAN-  
TIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on  
how long an implied warranty lasts, so the above limitation may not apply if it is incon-  
sistent with the controlling state law.  
This limited warranty excludes failures not caused by a defect in material or workman-  
ship.This limited warranty does not cover damage due to accidents, abuse or improper  
handling, maintenance or use. This limited warranty also does not cover any engine that  
has been structurally altered, or when the vehicle has been used in racing competition.  
This limited warranty also does not cover physical damage, corrosion or defects caused  
by fire, explosions or other similar causes beyond the control of Polaris.  
Owners are responsible for performing the scheduled maintenance identified in the  
owner's manual. Polaris may deny warranty claims for failures that have been caused by  
the owner’s or operator’s improper maintenance or use, by accidents for which Polaris  
has no responsibility, or by acts of God.  
Any qualified repair shop or person may maintain, replace, or repair the emission con-  
trol devices or systems on your vehicle. Polaris recommends that you contact an autho-  
rized Polaris dealer to perform any service that may be necessary for your vehicle.  
Polaris also recommends that you use only Pure Polaris parts. It is a potential violation  
of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the  
effectiveness of the vehicle's emission controls. Tampering with emission controls is  
prohibited by federal law.  
If you have any questions regarding your warranty rights and responsibilities, please  
contact the Polaris Warranty Department at 1-888-704-5290.  
128  
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MAINTENANCE LOG  
Present this section of your manual to your dealer each time your vehicle is serviced.  
This will provide you and future owners with an accurate log of maintenance and ser-  
vices performed.  
DATE  
MILES (KM)  
OR HOURS  
TECHNICIAN  
SERVICE PERFORMED / COMMENTS  
129  
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MAINTENANCE LOG  
DATE  
MILES (KM)  
OR HOURS  
TECHNICIAN  
SERVICE PERFORMED / COMMENTS  
130  
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INDEX  
A
C
Accessories . . . . . . . . . . . . . . . . . . . 111  
Air Filter . . . . . . . . . . . . . . . . . . . . . . 83  
All Wheel Drive System. . . . . . . . . . 33  
Apparel, Protective . . . . . . . . . . . . . . 12  
Auxiliary Foot Brake . . . . . . . . . . . . 78  
AWD Switch. . . . . . . . . . . . . . . . 24, 33  
AWD System . . . . . . . . . . . . . . . . . . 33  
Coolant Bottle. . . . . . . . . . . . . . . . . . 76  
Coolant, Radiator . . . . . . . . . . . . . . . 77  
Cooling System. . . . . . . . . . . . . . 76-77  
Corrosion Removal, Chrome . . . . . 108  
Crankcase Emission Control System 61  
D
Demand Drive Capacities. . . . . . . . . 74  
Drive Belt Wear/Burn. . . . . . . . . . . 113  
Drivetrain Break-In. . . . . . . . . . . . . . 42  
Driving Downhill . . . . . . . . . . . . . . . 53  
Driving in Reverse . . . . . . . . . . . . . . 57  
Driving on a Sidehill. . . . . . . . . . . . . 52  
Driving on Slippery Surfaces . . . . . . 50  
Driving Over Obstacles . . . . . . . . . . 56  
Driving Procedures . . . . . . . . . . . . . . 48  
Driving Through Water . . . . . . . . . . 55  
Driving Uphill. . . . . . . . . . . . . . . . . . 51  
B
Battery . . . . . . . . . . . . . . . . . . . 97-102  
Charging (Conventional) . . . . . . 101  
Charging (Sealed) . . . . . . . 101-102  
Fluid (Conventional) . . . . . . . . . 100  
Installation . . . . . . . . . . . . . . . . . . 99  
Removal . . . . . . . . . . . . . . . . . . . . 98  
Storage . . . . . . . . . . . . . . . . . . . . 100  
Belt Life . . . . . . . . . . . . . . . . . . . . . . 32  
Boots . . . . . . . . . . . . . . . . . . . . . . . . . . 9  
Brake Fluid, Auxiliary Foot Brake . . 30  
Brake Fluid, Main Brake System . . . 28  
Brake Lever. . . . . . . . . . . . . . . . . . . . 27  
Brake, Foot . . . . . . . . . . . . . . . . . 30, 78  
Brake, Hand Lever . . . . . . . . . . . . . . 78  
Brake, Parking . . . . . . . . . . . . . . . . . 29  
Brakelight Lamp Replacement . . . . . 89  
Brakes . . . . . . . . . . . . . . . . . . . . . . . . 78  
Break-In Period. . . . . . . . . . . . . . 41-42  
Breather Filter. . . . . . . . . . . . . . . . . . 84  
Breather Hose . . . . . . . . . . . . . . . . . . 84  
E
Electromagnetic Interference . . . . . . 61  
Emissions Limited Warranty . 127-128  
Engaging AWD . . . . . . . . . . . . . . . . 33  
Engine Break-In . . . . . . . . . . . . . . . . 42  
Engine Fogging. . . . . . . . . . . . . . . . 110  
Engine Idle RPM Adjustment. . . . . 104  
Engine Oil. . . . . . . . . . . . . . . . . . 68-69  
Equipment Modifications . . . . . . . . . . 9  
Etiquette, Trail Riding . . . . . . . . . . . 44  
Exhaust Emission Control System . . 61  
Eye Protection. . . . . . . . . . . . . . . . . . . 9  
C
Camber Adjustment . . . . . . . . . . . . 103  
Carburetor . . . . . . . . . . . . . . . . . . . . 104  
Carburetor Adjustment . . . . . . . . . . 104  
Cargo. . . . . . . . . . . . . . . . . . . . . . 58-59  
Caster Adjustment. . . . . . . . . . . . . . 103  
Choke . . . . . . . . . . . . . . . . . . . . . . . . 31  
Chrome Wheel Care . . . . . . . . . . . . 108  
Cleaning and Storage . . . . . . . 106-111  
Clothing . . . . . . . . . . . . . . . . . . . . . . . 9  
Clutching Chart. . . . . . . . . . . . . . . . 119  
Consumer Product Safety . . . . . . . . . 7  
F
Fluid, Brake . . . . . . . . . . . . . . . . 28, 30  
Fluid, Demand Drive . . . . . . . . . 74-75  
Fluid Change, Demand Drive. . . . . . 75  
Foot Brake, Auxiliary . . . . . . . . . . . . 30  
Footwell Removal. . . . . . . . . . . . . . . 80  
Fuel Filter . . . . . . . . . . . . . . . . . . . . . 31  
Fuel Recommendations . . . . . . . . . . 31  
Fuel Safety . . . . . . . . . . . . . . . . . . . . 11  
Fuel Tank Cap. . . . . . . . . . . . . . . . . . 31  
131  
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INDEX  
F
L
Fuel Valve . . . . . . . . . . . . . . . . . . . . 31  
Fuse Replacement . . . . . . . . . . . . . . 85  
Low Range Use . . . . . . . . . . . . . . . . . 96  
Lower Headlamp Replacement . . . . . 89  
Lubrication Guide . . . . . . . . . . . . . . . 67  
G
M
Gasoline Handling . . . . . . . . . . . . . . 11  
Gear Selector . . . . . . . . . . . . . . . . . . 32  
Gloves . . . . . . . . . . . . . . . . . . . . . . . . 9  
Maintenance Chart. . . . . . . . . . . . 62-66  
Master Cylinder. . . . . . . . . . . . . . . . . 28  
Mode Switch . . . . . . . . . . . . . . . . . . . 24  
Modifications. . . . . . . . . . . . . . . . . . . . 9  
H
Hand Brake . . . . . . . . . . . . . . . . . . . 78  
Handlebar Adjustment. . . . . . . . . . 103  
Hauling Cargo . . . . . . . . . . . . . . . 58-59  
Headlight Housing Replacement. . . 88  
Headlight Lamp Replacement . . . . . 86  
Headlight Switch . . . . . . . . . . . . . . . 25  
Helmet . . . . . . . . . . . . . . . . . . . . . . . . 8  
High Beam Adjustment . . . . . . . . . . 87  
High Range Use. . . . . . . . . . . . . . . . 96  
N
Noise Emission Control System . . . . 61  
O
Oil, Engine. . . . . . . . . . . . . . . . . . 68-69  
Oil, Transmission. . . . . . . . . . . . . 73-74  
Oil and Filter Change . . . . . . . . . 70-72  
Oil Level, Engine. . . . . . . . . . . . . . . . 69  
Oil Pump Priming . . . . . . . . . . . . . . . 72  
Oil Recommendations . . . . . . . . . . . . 68  
Operation on Public Lands . . . . . . . . 61  
Override Switch. . . . . . . . . . . . . . . . . 24  
I
Idle RPM Adjustment . . . . . . . . . . 104  
Immersion Maintenance . . . . . . . . . 92  
Instrument Cluster . . . . . . . . . . . . 34-40  
P
J
Parking Brake . . . . . . . . . . . . . . . . . . 29  
Parking on an Incline. . . . . . . . . . . . . 60  
Periodic Maintenance Chart . . . . 62-66  
Polaris Product List . . . . . . . . . . . . . 117  
Polishing the Vehicle. . . . . . . . . . . . 107  
Pre-Ride Checklist. . . . . . . . . . . . . . . 45  
PVT Break-In . . . . . . . . . . . . . . . . . . 42  
PVT Drying . . . . . . . . . . . . . . . . . . . . 96  
PVT System. . . . . . . . . . . . . . . . . 94-96  
Jetting Chart. . . . . . . . . . . . . . . . . . 119  
K
Key Switch. . . . . . . . . . . . . . . . . . . . 25  
K-Turn . . . . . . . . . . . . . . . . . . . . . . . 54  
L
Lights . . . . . . . . . . . . . . . . . . . . . 86-89  
Headlight Housing Replacement 88  
Headlight Lamp . . . . . . . . . . . . . 86  
High Beam Adjustment . . . . . . . 87  
Low Beam Adjustment . . . . . . . . 87  
Lower Headlamp Replacement. . 89  
Taillight/Brakelight. . . . . . . . . . . 89  
Low Beam Adjustment . . . . . . . . . . 87  
R
Reverse Operation . . . . . . . . . . . . . . . 57  
Reverse Override Switch. . . . . . . . . . 24  
Rider Information Center. . . . . . . 35-40  
Riding Area . . . . . . . . . . . . . . . . . . . . 44  
Riding Gear . . . . . . . . . . . . . . . . . . . 8-9  
132  
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INDEX  
S
T
Safe Operation Practices. . . . . . . . . . 43  
Safety Decals . . . . . . . . . . . . . . . 21-23  
Safety Labels  
Taillight Lamp Replacement . . . . . . 89  
Throttle Cable Freeplay Adjustment 105  
Throttle Lever . . . . . . . . . . . . . . . . . . 26  
Tire Tread Depth. . . . . . . . . . . . . . . . 81  
Tires . . . . . . . . . . . . . . . . . . . . . . 81-82  
Wheel Installation . . . . . . . . . . . . 82  
Wheel Nut Torque . . . . . . . . . . . . 82  
Wheel Removal . . . . . . . . . . . . . . 81  
Toe Alignment . . . . . . . . . . . . . . . . . 79  
Towing Loads . . . . . . . . . . . . . . . . . . 59  
Trail Etiquette . . . . . . . . . . . . . . . . . . 44  
Training. . . . . . . . . . . . . . . . . . . . . . . . 7  
Transmission. . . . . . . . . . . . . . . . . . . 32  
Transmission Oil. . . . . . . . . . . . . 73-74  
Transporting the ATV. . . . . . . . . . . 112  
Tread Lightly . . . . . . . . . . . . . . . . . . 44  
Turning Around on a Hill . . . . . . . . . 54  
Turning the Vehicle . . . . . . . . . . . . . 49  
"No Passenger" Warning . . . . . . . 22  
Age 16 Warning. . . . . . . . . . . . . . 22  
Clutch Cover Warning . . . . . . . . . 23  
Discretionary Warning. . . . . . . . . 21  
General Warning . . . . . . . . . . . . . 21  
Rack Warning, Front and Rear . . 23  
Reverse Override Warning. . . . . . 23  
Tire Pressure/Load Warning . . . . 22  
Safety Training . . . . . . . . . . . . . . . . . . 7  
Safety Warnings . . . . . . . . . . . . . 10-20  
Service Interval Programming . . . . . 39  
Severe Use . . . . . . . . . . . . . . . . . . . . 62  
Side Panel Removal . . . . . . . . . . . . . 80  
Sidehilling. . . . . . . . . . . . . . . . . . . . . 52  
Signal Words. . . . . . . . . . . . . . . . . . . . 4  
Spark Arrestor. . . . . . . . . . . . . . . . . . 93  
Spark Plug Inspection . . . . . . . . . 90-91  
Spark Plug Recommendations . . . . . 90  
Spark Plug Torque Specification . . . 90  
Spark Plugs . . . . . . . . . . . . . . . . . 90-91  
Specifications . . . . . . . . . . . . . 118-119  
Spring Adjustment, Rear Shock . . . 103  
Starting the Engine . . . . . . . . . . . 46-47  
Steering Assembly . . . . . . . . . . . . . . 80  
Storage . . . . . . . . . . . . . . . . . . 106-111  
Storage Tips . . . . . . . . . . . . . . 109-111  
Switches  
V
Vehicle Identification Numbers . . . . . 6  
Vehicle Immersion . . . . . . . . . . . . . . 92  
VIN . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  
W
Warning Symbols . . . . . . . . . . . . . . . . 4  
Washing the Vehicle. . . . . . . . 106-107  
Wheel Hub Tightening . . . . . . . . . . . 81  
Wheel Installation. . . . . . . . . . . . . . . 82  
Wheel Nut Torque Specifications. . . 82  
Wheel Removal . . . . . . . . . . . . . . . . 81  
AWD Switch . . . . . . . . . . . . . 24, 33  
Engine Stop Switch . . . . . . . . . . . 25  
Headlight Switch . . . . . . . . . . . . . 25  
Main Key Switch . . . . . . . . . . . . . 25  
Mode/Reverse Override Switch. . 24  
133  
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