Polaris Offroad Vehicle Scrambler 50 User Manual

2003

ATV

Universal

Owner's Manual

for

Vehicle 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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S Technical tips

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S Event schedules

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Check it out...

www.polarisindustries.com/owner

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All information in this manual is based on the latest product data and specifications

available at the time of printing. Polaris Industries Inc. reserves the right to make product

changes and improvements that may affect illustrations or explanations.

No part of this manual shall be reproduced or used without the written permission of

Polaris Industries Inc.

Printed in the U.S.A.

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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.

Polaris Recreational and Utility Vehicles

S Snowmobiles

S All-terrain vehicles (ATVs)

S Personal watercraft

S Victory motorcycles

S RANGER utility vehicles

Polaris Professional Series Workmobilest

S Utility Task Vehiclest (UTVs)

S Personal Task Vehiclest (PTVs)

S All-Surface Loaders (ASLs)

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

recreational vehicles manufactured in the world today. Many years of

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

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

produced.

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

instructions and recommendations in this owner’s manual. Your

manual contains instructions for minor maintenance, but information

about major repairs is outlined in the Polaris Service Manual and

should be performed only by a Factory Certified Master Service Dealer

(MSD) Technician.

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

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

service needs during, and after, the warranty period.

We also take great pride in our Parts Apparel and Accessories (PAA)

products, available through our online store at www.purepolaris.com.

Have your accessories and clothing delivered right to your door!

Polaris, Polaris The Way Out, and Workmobiles are registered

trademarks of Polaris Industries Inc.

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TABLE OF CONTENTS

WELCOME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . 5

VEHICLE IDENTIFICATION NUMBERS . . . . . . . . 6

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

NOISE EMISSION CONTROL

SYSTEM REGULATION . . . . . . . . . . . . . . . . . . 74

MAINTENANCE AND LUBRICATION . . . . . . . . . 75

POLARIS RECOMMENDED PRODUCTS . . . . 141

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . 142

WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

NOTE: Illustrations used in this manual are for general representation

only. Your model may differ.

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VEHICLE IDENTIFICATION NUMBERS

The vehicle frame vehicle identification number (VIN)(1) and engine

serial number (2) are important for model identification when

registering your vehicle, when obtaining insurance, and when ordering

replacement parts. If your vehicle is stolen, these numbers are essential

to the recovery and identification of your vehicle.

Remove the spare key and store it in a safe place. Your key can be

duplicated only by mating a Polaris key blank with one of your

existing keys. If both keys are lost, the ignition switch must be

replaced. See your Polaris dealer.

NOTE: Record your vehicle’s ID numbers and key number (3) in the

spaces provided.

31XX

Frame VIN:

Vehicle Model Number:

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

Key Number:

Dealer Imprint:

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SAFETY

Operator Safety

WARNING

Failure to follow the warnings 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 and understand your owner’s manual and all warnings

before operating a Polaris ATV.

Age Restrictions

This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited

for anyone under 16 years of age.

Know Your Vehicle

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

safety, the safety of others, and the protection of our environment.

Read and understand your owner’s manual, which includes valuable

information about all aspects of your vehicle, including safe operating

procedures.

Safety Training

When you purchased your new ATV, your dealer offered a hands-on

safety training course that covers all aspects of vehicle safety. 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 from a party other than a Polaris

dealer, you can request this free safety training from any authorized

Polaris dealer.

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 vehicle are thoroughly inspected at specific

intervals.

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SAFETY

Operator Safety

The following signal words and symbols appear throughout this

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

and symbols are used. Become familiar with their meanings before

reading the manual.

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

to the potential for personal injury.

WARNING

The safety alert warning indicates a potential hazard that may result

in serious injury or death.

CAUTION

The safety alert caution indicates a potential hazard that may result

in minor personal injury or damage to the machine.

CAUTION

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

machine.

NOTE

A note will alert you to important information or instructions.

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SAFETY

Operator Safety

WARNING

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

instructions and procedures, which are outlined in further detail

within your owner’s manual.

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

procedures described.

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

course. Beginners should receive training from a certified instructor.

Contact an authorized Polaris ATV dealer or call Polaris at

1-800-342-3764 to find out about the training courses nearest you.

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

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

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

ty training course.

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

walks, driveways, parking lots, and streets.

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

a dirt or gravel road.

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

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

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

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

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

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

S Never attempt wheelies, jumps or other stunts.

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

operating condition. Always follow the inspection and maintenance

procedures and schedules outlined in your owner’s manual.

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

rests of the ATV during operation.

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

miliar terrain. Be alert to changing terrain conditions.

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

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

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

speeds. Do not turn at excessive speeds.

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SAFETY

Operator Safety

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

it’s been involved in an accident.

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

Practice on smaller hills before attempting larger hills.

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

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

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

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

the top of a hill at high speed.

S Always follow proper procedures for going downhill and for braking

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

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

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

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

sible.

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

Avoid hills with excessively slippery or loose surfaces. Shift your

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

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

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

steep hill when possible.

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

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

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

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

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

Turn the ATV around and remount following the procedure de-

scribed in this manual.

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

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

Always follow proper procedures when operating over obstacles as

described in this manual.

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

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

ding or sliding out of control.

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

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

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

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

changes.

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SAFETY

Operator Safety

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

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

friction to dry out the pads.

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

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

avoid turning at sharp angles.

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

always maintain proper tire pressure.

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

sories.

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

properly distributed and securely attached. Reduce speed and follow

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

greater distance for braking.

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

prevent unauthorized use or accidental starting.

FOR MORE INFORMATION ABOUT ATV SAFETY, call the Con-

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

Polaris at 1-800-342-3764.

Equipment Modifications

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

public. Therefore, we strongly recommend that consumers do not

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

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

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

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

injury.

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

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

the vehicle, that increase its speed or power.

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

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

handling characteristics of the vehicle. Use only Polaris-approved

accessories, and familiarize yourself with their function and effect on

the vehicle.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating this ATV without proper instruction.

WHAT CAN HAPPEN

The risk of an accident is greatly increased if the operator

does not know how to operate the ATV properly in different

situations and on different types of terrain.

HOW TO AVOID THE HAZARD

Beginning and inexperienced operators should complete the

certified training course offered by Polaris. Operators should

regularly practice the skills learned in the course and the

operating techniques described in the owner’s manual.

For more information about the training course, contact an

authorized ATV dealer or call Polaris at 1-800-342-3764.

WARNING

POTENTIAL HAZARD

Failure to follow the age recommendations for this ATV.

WHAT CAN HAPPEN

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

minimum age recommendation operates an ATV.

Even though a child may be within the recommended age group

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

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

be susceptible to accident or injury.

HOW TO AVOID THE HAZARD

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

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Carrying a passenger on an ATV.

WHAT CAN HAPPEN

Carrying a passenger greatly reduces the operator’s ability to

balance and control the ATV, which could cause an accident

and injury to the operator and/or passenger.

HOW TO AVOID THE HAZARD

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

allow the operator to shift position as needed during operation.

It is not intended for carrying passengers.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating an ATV on paved surfaces, including sidewalks,

paths, parking lots, and driveways.

WHAT CAN HAPPEN

ATV tires are designed for off-road use. Operating on paved

surfaces may seriously affect the handling and control of the

ATV and could result in loss of control, accident, and/or injury.

HOW TO AVOID THE HAZARD

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

travel slowly and avoid sudden turns or stops.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating this ATV on public streets, roads or highways.

WHAT CAN HAPPEN

The ATV could collide with another vehicle.

HOW TO AVOID THE HAZARD

Never operate the ATV on any public street, road or highway,

including dirt and gravel roads. In many states it’s illegal to

operate ATVs on public streets, roads and highways.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating this ATV without wearing an approved helmet, eye

protection and protective clothing.

WHAT CAN HAPPEN

Operating an ATV without an approved helmet increases the

risk of a severe head injury or death in the event of an

accident.

Operating without eye protection could result in an accident

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

of an accident.

HOW TO AVOID THE HAZARD

Always wear an approved helmet that fits properly.

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

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

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating the ATV after consuming alcohol or drugs.

WHAT CAN HAPPEN

Consumption of alcohol and/or drugs could seriously affect

operator judgment. Reaction time may be slower and operator

balance and perception could be affected.

Consuming alcohol and/or drugs before or while operating an

ATV could result in an accident causing severe injury or death.

HOW TO AVOID THE HAZARD

Never consume alcohol or drugs before or while operating an

ATV.

WARNING

POTENTIAL HAZARD

Operating the ATV at excessive speeds.

WHAT CAN HAPPEN

Excessive speed increases the operator’s chance of losing

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

HOW TO AVOID THE HAZARD

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

visibility and operating conditions, and your experience.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Attempting wheelies, jumps and other stunts.

WHAT CAN HAPPEN

Attempting stunts increases the chance of an accident, including

an overturn.

HOW TO AVOID THE HAZARD

Never attempt wheelies, jumps, or other stunts. Avoid exhibition

driving.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Failure to inspect the ATV before operating.

Failure to properly maintain the ATV.

WHAT CAN HAPPEN

Poor maintenance increases the possibility of an accident or

equipment damage.

HOW TO AVOID THE HAZARD

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

safe operating condition.

Always follow the inspection and maintenance procedures and

schedules described in the owner’s manual.

WARNING

POTENTIAL HAZARD

Removing hands from the handlebars or feet from the

footrests during operation.

WHAT CAN HAPPEN

Removing even one hand or foot can reduce ability to

control the vehicle or could cause loss of balance and

ejection from the ATV.

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

could come into contact with the rear wheels and lead to

accident or injury.

HOW TO AVOID THE HAZARD

Always keep both hands on the handlebars and both feet

on the footrests of the ATV during operation.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Failure to use extra caution when operating the ATV on unfamiliar

terrain.

WHAT CAN HAPPEN

Unfamiliar terrain may contain hidden rocks, bumps, or holes that

could cause loss of control or overturn.

HOW TO AVOID THE HAZARD

Travel slowly and use extra caution when operating on unfamiliar

terrain. Always be alert to changing terrain conditions.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Failure to use extra caution when operating on excessively

rough, slippery or loose terrain.

WHAT CAN HAPPEN

Operating on excessively rough, slippery or loose terrain could

cause loss of traction or loss of control, which could result in an

accident or overturn.

HOW TO AVOID THE HAZARD

Do not operate on excessively rough, slippery or loose terrain

until you’ve learned and practiced the skills necessary to

control the ATV on such terrain.

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

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Turning improperly.

WHAT CAN HAPPEN

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

or overturn.

HOW TO AVOID THE HAZARD

Always follow proper procedures for turning as described in the

owner’s manual.

Practice turning at slow speeds before attempting to turn at

faster speeds.

Never turn at excessive speed.

WARNING

POTENTIAL HAZARD

Operating on excessively steep hills.

WHAT CAN HAPPEN

The vehicle may overturn.

HOW TO AVOID THE HAZARD

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

abilities. Never operate the ATV on hills steeper than 25_.

Practice on smaller hills before attempting large hills.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Climbing hills improperly.

WHAT CAN HAPPEN

Improper hill climbing could cause loss of control or overturn.

HOW TO AVOID THE HAZARD

Always follow proper procedures for climbing hills as described

in the owner’s manual.

Always check the terrain carefully before ascending any hill.

Never operate the ATV on hills steeper than 25_.

Never climb hills with excessively slippery or loose surfaces.

Shift your weight forward.

Never open the throttle suddenly while traveling uphill. The ATV

could flip over backwards.

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

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

side of the hill.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Traveling downhill improperly.

WHAT CAN HAPPEN

Improperly descending a hill could cause loss of control or

overturn.

HOW TO AVOID THE HAZARD

Always follow proper procedures for traveling down hills as

described in the owner’s manual. NOTE: A special technique

is required when braking while traveling downhill. See page

68.

Always check the terrain carefully before you descending a hill.

Shift your weight backward.

Never travel down a hill at high speed.

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

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

hill when possible.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Improperly crossing hills and turning on hills.

WHAT CAN HAPPEN

Improperly crossing or turning as hills could cause loss of control

or overturn.

HOW TO AVOID THE HAZARD

Never attempt to turn the ATV around on any hill until you’ve

mastered the turning technique (on level ground) as described in

the owner’s manual. See page 69. Use extra caution when

turning on any hill.

Avoid crossing the side of a steep hill.

When crossing the side of a hill:

Always follow proper procedures as described in the owner’s

manual.

Avoid hills with excessively slippery or loose surfaces.

Shift your weight to the uphill side of the ATV.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Stalling, rolling backwards or

improperly dismounting while

climbing a hill.

WHAT CAN HAPPEN

The vehicle could overturn.

HOW TO AVOID THE

HAZARD

Maintain steady speed when

climbing a hill.

If all forward speed is lost:

Keep your weight uphill.

Apply the single lever brake gradually.

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

lock the parking brake.

If the ATV begins rolling backwards:

Keep weight uphill.

Never apply engine power.

Never apply the auxiliary rear brake while rolling backwards.

Apply the single-lever brake gradually.

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

then lock the parking brake.

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

straight uphill.

Turn the ATV around and remount, following the procedure

described in the owner’s manual. See page 69.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Improperly operating over obstacles.

WHAT CAN HAPPEN

Operating over obstacles could cause loss of control or overturn.

HOW TO AVOID THE HAZARD

Before operating in a new area, check for obstacles.

Avoid operating over large obstacles such as rocks and fallen

trees when possible. If unavoidable, use extreme caution and

always follow proper procedures as outlined in the owner’s

manual.

WARNING

POTENTIAL HAZARD

Skidding or sliding.

WHAT CAN HAPPEN

Skidding or sliding can cause loss of control.

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

HOW TO AVOID THE HAZARD

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

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

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating the ATV through deep or fast-flowing water.

WHAT CAN HAPPEN

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

which could lead to an accident or overturn.

HOW TO AVOID THE HAZARD

Avoid operating the ATV through deep or fast-flowing water.

If it’s unavoidable to enter water that exceeds the

recommended maximum depth (see page 70), travel slowly,

balance your weight carefully, avoid sudden movements, and

maintain a slow and steady forward motion. Do not make

sudden turns or stops, and do not make sudden throttle

changes.

Wet brakes may have reduced stopping ability. Always test

the brakes after leaving water. If necessary, apply them

several times to let friction dry out the pads.

WARNING

POTENTIAL HAZARD

Improperly operating in reverse.

WHAT CAN HAPPEN

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

severe injury.

HOW TO AVOID THE HAZARD

Before shifting into reverse gear, always check for obstacles or

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

slowly.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating this ATV with improper tires, or with improper or uneven

tire pressure.

WHAT CAN HAPPEN

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

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

HOW TO AVOID THE HAZARD

Always use the size and type of tires specified in the owner’s

manual supplement for the ATV.

Always maintain proper tire pressure as described in the owner’s

manual supplement.

WARNING

POTENTIAL HAZARD

Operating the ATV with improper modifications.

WHAT CAN HAPPEN

Improper installation of accessories or modification of the ATV

may cause changes in handling which could lead to an

accident.

HOW TO AVOID THE HAZARD

Never modify the ATV through improper installation or use of

accessories. All parts and accessories added to the vehicle

must be genuine Polaris Industries Inc. or equivalent

components designed for use on this ATV and should be

installed and used according to approved instructions. See

your authorized Polaris ATV dealer for more information.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Overloading the ATV or carrying/towing cargo improperly.

WHAT CAN HAPPEN

Overloading and towing can cause changes in vehicle handling,

which could lead to loss of control or an accident.

HOW TO AVOID THE HAZARD

Never exceed the stated load capacity for this ATV.

Cargo should be properly distributed and securely attached.

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

greater distance for braking.

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

cargo or pulling a trailer. See page 61.

WARNING

POTENTIAL HAZARD

Operating on frozen bodies of water.

WHAT CAN HAPPEN

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

fall through the ice.

HOW TO AVOID THE HAZARD

Never operate the ATV on a frozen body of water. If you’re

confident that the ice is thick enough and sound enough to

support the machine and its operator, as well as the force

created by a moving vehicle, exercise extreme caution.

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SAFETY

Operator Safety

WARNING

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

the vehicle resulting in serious injury or death. Always remove

the ignition key when the vehicle is not in use.

WARNING

After any overturn or accident, have a qualified service dealer

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

limited to) brakes, throttle and steering systems.

WARNING

Safe operation of this rider-active vehicle requires good judgement

and physical skills. Persons with cognitive or physical disabilities

who operate this vehicle have an increased risk of overturn and

loss of control, which could result in severe injury or death.

CAUTION

Always keep combustible materials away from the exhaust

system. Exposure to the hot components could result in a fire.

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SAFETY

Safety Decals and Locations

Warning decals have been placed on the ATV for your protection.

Read and follow the instructions on each decal carefully. If a decal

becomes illegible or comes off, contact your Polaris dealer to purchase

a replacement. Replacement safety decals are provided by Polaris at no

charge. The part number is printed on the decal.

WARNING

DNever operate this vehicle on HILLS steeper than 25 degrees 25°.

To prevent flipover on hilly terrain, when going up or down, use

throttle and brakes gradually.

^DREVERSE operation can be dangerous, even at low

speeds. Steering becomes difficult. To prevent flipover,

avoid sudden braking or sharp turns.

DUse OVERRIDE for reverse speed limiter with caution.

To prevent loss of control, neveractivate override button

with open throttle.

DPARKING BRAKE may relax when used for more than

5 minutes. When parking on grades, leave shift in for-

ward.

7079085

Non-drum shift models

WARNING

DNever operate this vehicle on HILLS steeper than 25 degrees 25°.

To prevent flipover on hilly terrain, when going up or down, use

throttle and brakes gradually.

^DREVERSE operation can be dangerous, even at low

speeds. Steering becomes difficult. To prevent flipover,

avoid sudden braking or sharp turns.

DUse OVERRIDE for reverse speed limiter with caution.

To prevent loss of control, neveractivate override button

with open throttle.

IF OWNER’S MANUAL IS MISSING, CONTACT

A POLARIS DEALER FOR A REPLACEMENT.

DWhen this ATV is not in operation, or unattended, place

shift in park position.

7171383

7079083

E1997, 2000

Drum shift models

WARNING

This ATV may exceed the perfor-

mance of other ATVs you may have

ridden in the past. This category S

(Sport) ATV is a high performance

vehicle for off road use only, in sport

type recreation and competitive use

by operators with advanced skills

and substantial experience.

Trail Blazer models

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SAFETY

WARNING

Safety Decals and Locations

WARNING

Operating this vehicle if you are under the age

of 16 increases your chance of severe injury

or death.

NEVER operate this vehicle if you are under

age 16.

WARNING

IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of

control resulting in SEVERE INJURY OR DEATH.

TIRE PRESSURE (PSI): FRONT ___ REAR ___

MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight)

INCLUDING MACHINE, DRIVER AND CARGO IS ____ LBS.

Reduce speed and allow greater distance for braking when carrying

cargo. Overloading or carrying tall, off-center, or unsecured loads

will increase your risk of losing control. Loads should be centered,

carried as low as possible, and firmly secured to the racks. with

dual racks, load distribution 1/3 front 2/3 rear is best. For stability

on rough or hilly terrain, reduce speed and cargo. Do not block

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

Read Owner’s Manual for more detailed loading information

See your Owner’s Manual Supplement for specifications.

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SAFETY

Safety Decals and Locations

WARNING

DO NOT TOW FROM RACK OR BUMPER.

Vehicle damage or tipover may result causing severe

injury or death. Tow only from tow hooks or hitch.

Maximum Rack Loads: Front 90 lbs. Rear 180 Lbs

7170021

On models with racks

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.

7078689

NO STEP

ATTENTION

DSpecific carburetor jetting

DOperation of this

and adjustments are

vehicle without the

required depending on temperature

and altitude. See your Owner’s Manual.

filter element will severely

damage the engine.

Factory setting:

DClean air filter often, more

frequent cleaning required

in dusty conditions

40_ to 80_ F. at 0-3000 feet (5_ to 27_

C. at 0-900 meters).

7079901

Under Seat

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SAFETY

Safety Decals and Locations

Chain Freeplay Is Important.

WARNING

Pushing reverse

override button

may cause

sudden in-

creases in pow-

er and traction if

too much

throttle is ap-

plied. Loss of

control or for-

ward flipover

may result, es-

pecially in

Adjust Freeplay to 3/16″ - 3/8″

DO NOT Overtension. See

Owner’s Manual.

OVERRIDE

SWITCH

Torque Nut on Eccentric Bolts:

To 30 Ft. Lbs.(For models

without a hitch).

Reverse Speed is

limited.

To 60 Ft. Lbs. (For models with

Reverse override is

controlled by the

override switch.

a hitch.

7078572

See your Owner’s

Manual.

AWD. See Own-

er’s Manual.

7079906

2WD Models

7079604

AWD Models

MANUFACTURED

ALL WHEEL

DRIVE

SWITCH

BY: POLARIS IND

DATE:

Do not push switch to

engage AWD if the rear

wheels are spinning.

This may cause severe

drive shaft and clutch

damage.

VIN:

THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND

IS NOT INTENDED FOR USE ON PUBLIC ROADS.

CE VÉHICULE EST UN VÉHICULE TOUT TERRAIN

QUI NiEST PAS DESTINÉ À ÊTRE UTILISÉ SUR

LES CHEMINS PUBLICS.

See your Owner’s

Manual.

PRINTED IN U.S.A.

7077185

7079780

Canadian Certification Decal

NOTE: Your ATV will not have all of the decals shown on this page.

Decals vary depending on the model you own.

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SAFETY

Safe Riding Gear

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

special protective clothing for comfort and to reduce the chance of

injury.

1. Helmet

Your helmet is the most important piece

of protective gear for safe riding. A

helmet can prevent a severe head injury.

Select an approved helmet that meets or

exceeds your state’s safety standards

and bears either the Department of

Transportation (DOT) label, the

American National Standards Institute

label (ANSI z90.1), or the Snell

Memorial Foundation label.

2. Eye Protection

Do not depend on sunglasses for proper

eye protection. A pair of goggles or a

helmet face shield offer the best

protection for your eyes. They should

be kept clean and be of shatterproof

design (bearing the markings z2.1 or

VESC 8).

3. Gloves

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

protection.

4. Boots

The best footwear is a pair of strong over-the-calf boots with heels, like

moto-cross boots.

5. Clothing

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

Riding pants with kneepads and a jersey with shoulder pads provide

the best protection.

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CONTROLS

Electrical Switches

WARNING

Activating the override switch while the throttle is open can cause

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

the override switch while the throttle is open.

Override Switch (1) (Reverse Speed Limiter) - This

OFF

RUN

vehicle is equipped with a reverse speed limiter

system. To gain additional power while backing,

depress the override switch. NOTE: The override

switch also allows activation of Demand 4 Drive

(All Wheel Drive) in reverse, if the Demand 4 Drive switch is on.

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

center “run” position and turn the main key switch clockwise past the

“on” position. Release the key when the engine starts. NOTE: Turn

off the main switch to end all electrical power to the vehicle, including

the cooling fan and lights.

WARNING

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

the vehicle resulting in serious injury or death. Always remove

the ignition key when the vehicle is not in use.

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

switch is in its “off” position. Its purpose is to provide the operator

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

stop the engine, slide the stop switch either right or left to the “off”

position. NOTE: Turning off the engine stop switch will shut off all

electrical power to the vehicle, with the exception of the cooling fan on

some models. On those models, use the main switch to shut off the

power to the cooling fan.

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CONTROLS

WARNING

Do not start or operate an ATV with sticking or improperly

operating throttle controls, which could cause an accident and

lead to severe injury or death.

Always contact your dealer for service repairs if throttle problems

arise.

Failure to check or maintain proper operation of the throttle

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

operation.

Always check the lever for free movement and return before

starting the engine. Also check occasionally during operation.

Throttle Lever

Engine speed and vehicle

movement are controlled by

pressing the throttle lever.

The throttle lever (1) is spring

loaded. Engine speed returns

to idle when the lever is

released.

This ATV is equipped with

Polaris Electronic Throttle Control

(ETC), which is designed to reduce the risk of a

frozen or stuck throttle. If the throttle cable should stick in an open

position when the operator releases the throttle lever, the engine will

stop, and power to the rear wheels will cease.

WARNING

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

event of a throttle system malfunction and is provided for your

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

with any after market throttle mechanisms.

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CONTROLS

WARNING

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

result in an accident and serious injury or death.

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

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

and drive at reduced speeds in conditions of reduced visibility such

as fog, rain and darkness.

Light Switches

The light switch is located on the

left handlebar (1). It’s used to turn

the lights on and off and to switch

the lights from HI to LO on models

equipped with HI-LO beams.

NOTE: The lights won’t work

unless the key is in the “on”

position and the shut-off switch is

in the “run” position.

Brakes

Check the brake fluid level in the master cylinder before each use of

the ATV. The master cylinder (2) is located on the left handlebar.

The fluid level can be seen through an indicator window (3) on the top

of the master cylinder. This “eye” will appear dark when the fluid

level is full. When fluid needs to be added, the eye will be clear.

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

ground with the handlebars straight. If the fluid level is low add DOT 3

brake fluid only. See page 141 for the part numbers of

Polaris-recommended products.

WARNING

After opening a bottle of brake fluid, always discard any unused

portion. Never store or use a partial bottle. Brake fluid is

hygroscopic, meaning it rapidly absorbs moisture from the air. The

moisture causes the boiling temperature of the brake fluid to drop,

which can lead to early brake fade and the possibility of accident or

severe injury.

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CONTROLS

Brake Lever

The front and rear brakes are applied

by squeezing the brake lever (1)

toward the handlebar. The front and

rear brakes are hydraulically activated

disc type brakes that are activated by

only one lever.

Always test brake lever travel and

master cylinder fluid level before

riding. When squeezed, the lever should feel firm. Any sponginess

would indicate a possible fluid leak or low master cylinder fluid level,

which must be corrected before riding. Contact your dealer for proper

diagnosis and repairs.

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.

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CONTROLS

Parking Brake

WARNING

Operating the ATV while the parking brake is engaged could

result in an accident and serious injury or death.

Always check to be sure the parking brake is disengaged

before operating.

Setting the Parking Brake

1. Squeeze and release the brake

lever (1) two or three times, then

squeeze and hold.

2. Push the park brake lock (2)

forward to engage the brake.

Release the brake lever.

3. To release the parking brake lock,

squeeze and release the brake

lever. It will return to its unlocked

position.

Important Safeguards

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

ways block the wheels to prevent rolling.

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

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

position.

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

hill. Always block the wheels to prevent rolling.

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CONTROLS

Auxiliary Brake

WARNING

Aggressively applying the rear brake when backing down a hill may

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

Use caution when applying the auxiliary brake. Do not

aggressively apply the auxiliary brake when going forward. The

rear wheels may skid and slide sideways, causing loss of control

and serious injury or death.

The auxiliary brake (1), is

located on the inside of the right

floor board and is operated by

the right foot. The auxiliary

brake serves as a backup to the

main brake system if the main

system becomes inoperative.

If the rear wheels slide while

using the auxiliary brake, reduce

brake pedal pressure to brake the

rear wheels without skidding.

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

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

the fluid level between the maximum and minimum marks.

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CONTROLS

Choke

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

procedure on page 59 for correct choke and throttle settings during

starting.

Fuel Valve

RES

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

the vehicle, either below the fender or on the

side panel. It has three positions:

OFF

OFF: For vehicle storage and when transporting.

ON: For normal operation.

RES: For reserve supply if main

supply is exhausted.

NOTE: There’s about a 7 to 10 mile

(11.2 to 16 km) range on reserve gas.

Always refill the gas tank as soon as

possible after using the reserve supply.

Always return valve to “on” position

after refueling.

Fuel Tank

The fuel tank filler cap (2) is located

directly below the handlebar. Use

either leaded or unleaded gasoline with

a minimum pump octane number of

87=(R+ M/2) octane. Refer to your

owner’s manual supplement for tank

capacity.

Fuel Filter

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

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

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CONTROLS

Fuel Safety

WARNING

Gasoline is highly flammable and explosive under certain

conditions.

S Always exercise extreme caution whenever handling gasoline.

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

well ventilated area.

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

area where refueling is performed or where gasoline is stored.

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

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

off with soap and water and change clothing.

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

exhaust fumes are poisonous and can cause loss of con-

sciousness or death in a short time.

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

WARNING

The engine exhaust from this product contains chemicals known

to cause cancer, birth defects or other reproductive harm.

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

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CONTROLS

Oil Injection Tank - 2-Cycle Models

CAUTION

Mixing brands or using a non-recommended oil may cause serious

engine damage. We recommend the use of Polaris Premium

Synthetic 2-cycle oil for your 2-cycle Polaris ATV. Never substitute or

mix oil brands.

To avoid serious engine damage, always top off the oil level when

refueling.

Models with 2-cycle engines have

oil injection. The oil injection tank

filler cap (1) is located on the front

of the vehicle. Tank capacity is

two quarts (1.9 l.).

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CONTROLS

Automatic Transmission Gear Selector

The transmission gear selector (1)

is located on the right side of the

vehicle. Shift patterns vary,

depending on your model.

H: High Gear

N: Neutral

L: Low Gear

R: Reverse

P: Park

CAUTION

Shifting gears with the engine speed above idle or while the

vehicle is moving could cause transmission damage.

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

move the lever to the desired gear.

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

gear with the parking brake locked.

Maintaining shift linkage adjustment is important to assure proper

transmission function. See your dealer if you experience any shifting

problems.

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.

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CONTROLS

Recoil Starter

If the battery is weak and cannot

start the engine, use of the recoil

starter (1) will allow vehicle

operation until repairs can be

made. The recoil starter is located

on the right side of the machine.

Polaris 4-cycle engines are

equipped with automatic

decompressors. This makes recoil

starting possible by allowing

compression to “leak” at cranking

speeds. The decompressor senses when the engine is spinning fast

enough to start and restores compression for starting.

1. Position the vehicle on a level surface and engage the parking

brake. See page 41.

2. Shift the transmission to Neutral.

3. Grasp the recoil starter rope handle tightly and pull slightly until

the starter mechanism engages.

4. Pull the rope abruptly to start the engine.

CAUTION

Extending the starter rope too far will cause damage to the recoil

assembly. Do not extend the starter rope so far that it stops.

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

the recoil housing and damage components. Make sure the

handle is fully seated on the recoil housing, especially when

traveling in wet areas.

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FEATURES

All Wheel Drive (AWD) System

Polaris 4 wheel drive ATVs are

equipped with a unique, Polaris

exclusive, Demand 4 Drive (AWD)

system that’s activated by a switch

(1) on the right handlebar. When the

switch is off, the ATV is in 2 wheel

drive at all times. When the switch

is on, the ATV is in Demand 4 Drive

and the AWD indicator light (2) will

be on.

When in AWD, the front hubs will

automatically engage any time the rear wheels lose traction. When the

rear wheels regain traction, the front hubs will automatically disengage.

NOTE: The override switch allows activation of Demand 4 Drive

(AWD) in reverse if the Demand 4 Drive switch is on. See page 37.

There is no limit to the length of time the vehicle may remain in

Demand 4 Drive.

Engaging Wheel Hubs

The Demand 4 Drive 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 front hubs are moving, the hubs will not disengage

until the rear wheels regain traction.

NOTE: Select AWD models do not have an AWD switch. These

models are continuously in AWD.

Engage the Demand 4 Drive switch before getting into conditions

where front wheel drive may be needed. If the rear wheels are

spinning, release the throttle before switching to Demand 4 Drive.

CAUTION

Switching to AWD while the rear wheels are spinning may cause

severe drive shaft and hub damage.

Always switch to AWD while the rear wheels have traction or are

at rest.

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FEATURES

All Wheel Drive (AWD) System

Disengaging Wheel Hubs

Although the hubs normally disengage when operating in reverse, one

or both hubs may occasionally remain engaged. If the handlebars pull

to one side, it’s likely that one front hub is engaged . If both hubs are

engaged, steering effort increases but remains balanced from left to

right, and vehicle speed is somewhat restricted.

Disengage the hubs by stopping, shifting to reverse, and backing for a

short distance. Then proceed in forward again.

NOTE: If the hubs remain engaged after following this procedure,

return the ATV to your dealer for service.

To continue using AWD in reverse, activate the override switch and the

Demand 4 Drive switch. See page 37.

WARNING

Operating with only one front hub engaged could result in loss of

control, accident, and severe injury or death.

When hub engagement symptoms are present, use the disengaging

procedure before proceeding.

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FEATURES

Indicator Lights

The configuration of the indicator lights differs with individual models.

Not every model is equipped with all of the lights, and the lights on

some models appear in the speedometer. The information in your

owner’s manual supplement and on this page will help you identify the

lights and their function.

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

time the ATV is used.

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

Turn the key off to prevent battery drain.

1. Transmission Neutral Indicator (green)

2. Transmission Low Gear Indicator (blue/grey)

3. Transmission Reverse Indicator (yellow)

4. Oil Warning (red)

On 2-cycle models, this light indicates a low oil level.

5. High Temp Warning (red)

This light will display if the engine overheats.

6. All Wheel Drive Indicator (red)

See page 48 for more information about AWD.

7. High Beam Indicator (blue)

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FEATURES

Instrument Cluster

Your ATV is equipped with an instrument cluster that senses vehicle

speed from the right front wheel. 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. Refer to page 37 for additional information.

1. Rider Information Center

2. Speedometer needle - in addition to depicting vehicle speed, this

needle will flash to signal a fault condition.

3. Speedometer

CAUTION

Washing the ATV with a high pressure washer may cause water to

enter the instrument cluster and cause damage to the electronic

components. Wash the ATV by hand or with a garden hose using

mild soap. Do not use alcohol to clean the instrument cluster.

Immediately clean off any gasoline that splashes on the instrument

cluster.

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FEATURES

Instrument Cluster

Rider Information Center

The rider information center is located in the lower portion of the

instrument cluster.

1. Gear Indicator - As the

shift lever is moved, this

will indicate the gear the

machine is in:

H = High Range

L = Low Range

N = Neutral

R = Reverse

P = Park

E or blank = Error - The

error message usually means

the gear selector is in between

gears. It can, however, also

indicate that the transmission

switch needs repair.

2. High Engine Coolant Temperature - Do not continue to operate the

ATV is this warning appears or serious engine damage could result.

3. Hour Meter

4. Service Interval/Miscellaneous Service Warnings

5. Low Battery and Over Voltage - This warning usually indicates

that the ATV is being operated at an RPM too low to keep the

battery charged. Driving at a higher RPM or connecting a battery

charger will usually clear the warning.

NOTE: All segments of the rider information center will light up for

2.5 seconds at start-up.

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FEATURES

Instrument Cluster

Rider Information Center

The rider information center has 4 standard modes:

Mode 1 - Odometer

Mode 2 - Tripmeter

Mode 3 - Total Service Hours

Mode 4 - Programmable service interval

The reverse override button on the left handlebar is also the mode

button. NOTE: If using the mode button to program the rider

information center, or to toggle through the options, the machine

cannot be in reverse.

Mode 1 - Odometer

The odometer records the miles traveled by the ATV.

Mode 2 -Trip Meter

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 . NOTE: In the Rider Information Center, the trip meter

display contains a decimal point, but the odometer displays without a

decimal point.

Mode 3 - Hour Meter

This mode logs the total hours the engine has been in operation.

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FEATURES

Instrument Cluster

Rider Information Center

Mode 4 - Programmable Service Interval

The purpose of the programmable service interval is to provide the

consumer and dealer with a convenient reminder for routine

maintenance. When your vehicle leaves the factory, this feature is

turned off. You must enable the programmable service interval before

it can be used.

Once the service interval mode is set with the hours when service is

due, the hours of actual engine operation are subtracted from the set

hours until 0 is reached. When the counter reaches 0, the wrench icon

will flash quickly for 5 seconds each time the vehicle is started as a

reminder that the periodic maintenance is due.

To set the hours, press and hold the mode/override button until the

wrench icon flashes. When it begins to flash, release the button. The

setting will increase by one hour each time the button is pressed.

Pressing and holding the button will allow the numbers to escalate

much faster. When the desired time increment is displayed, release the

button and wait for the wrench to stop flashing. When the wrench

stops blinking, your service hours are set. NOTE: If you scroll past

the intended number, hold the button down until the count turns over to

0. You can then reset the number.

If the service interval is enabled on your ATV and you wish to turn it

off, toggle to the service interval mode. Press and hold the mode

button for approximately 7 seconds until the word OFF appears in the

Rider Information Center.

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FEATURES

Instrument Cluster

Rider Information Center

Diagnostic Mode

The diagnostic mode is for informational purposes only. Please return

your ATV to your dealer for all major repairs.

To enter the diagnostics mode:

1. Turn the key switch off and wait 20 seconds.

2. Set the park brake and shift the transmission to neutral.

3. Hold the mode/reverse override button and turn the key switch on.

The initial screen displayed looks

similar to the top illustration and

refers to the software version

installed in your ATV. This

information is displayed briefly.

Use the mode/reverse override

button to toggle through the

diagnostic screens. The first

screen (1) displays battery

voltage.

The second screen (2) provides

full diagnostics for the entire oil

pressure electrical circuit. Along

with the letters PrSSr, there will

be a box on the left side. If the

box is high, the pressure is

normal. If the box is low, the

pressure is low.

Screen three (3) is the tachometer

for setting idle speed. If this

needs adjustment, please contact

your dealer.

As long as the center is in the

diagnostic mode, the wrench icon

will remain lit.

To leave the diagnostic mode,

either shift the machine out of

neutral or turn the key switch off

and on. NOTE: Any movement

of the tires will also take the machine out of the diagnostic mode.

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OPERATION

Break-In Period

2-Cycle Engines

The break-in period for your new Polaris ATV is defined as the time it

takes to use the first tank of fuel. No single action on your part is as

important as following the procedures for a proper break-in. Careful

treatment of a new engine will result in more efficient performance and

longer life for the engine. Perform the following procedures carefully.

CAUTION

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

damage close-fitted engine parts. Do not operate at full throttle or

high speeds for extended periods during the first three hours of

use.

Use of any oils other than those recommended by Polaris may

cause serious engine damage. We recommend the use of Polaris

2-cycle oil for your 2-cycle engine.

Lack of proper lubrication will cause serious engine damage.

Always fill the oil tank when refueling the ATV.

The first tank of fuel must be pre-mixed according to the following

instructions. After the break-in period, the oil injection system will

provide the necessary engine lubrication without pre-mixing.

1. Mix 12.8 ounces of Polaris 2-cycle oil to four gallons (or 16

ounces to five gallons) of gasoline in a suitable gas container. Fill

the fuel tank. See page 43.

2. Fill the oil tank with Polaris 2-cycle oil.

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

familiarize yourself with vehicle operation and handling.

4. Vary the throttle positions.

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

on the daily pre-ride inspection checklist. See page 58.

After the first tank of pre-mixed fuel has been used, verify that the oil

level in the oil tank has dropped, indicating that the oil pump is

functioning properly. If the level has not dropped, see your dealer for

oil pump bleeding and repeat the pre-mix procedure.

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OPERATION

Break-In Period

4-Cycle Engines

The break-in period for your new Polaris ATV is defined as the first ten

hours of operation, or the time it takes to use the first two full tanks of

gasoline. No single action on your part is as important as following

the procedures for a proper break-in. Careful treatment of a new

engine will result in more efficient performance and longer life for the

engine. Perform the following procedures carefully.

CAUTION

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

damage close-fitted engine parts. Do not operate at full throttle or

high speeds for extended periods during the first three hours of

use.

Use of any oils other than those recommended by Polaris may

cause serious engine damage. We recommend the use of Polaris

Premium 4 Synthetic Oil for your 4-cycle engine.

1. Fill the fuel tank with

ADD 8 OZ.

NORMAL

FULL

gasoline. See page 43.

2. Check the oil level on

the dipstick. See page

98. Add Polaris

Premium 4 Synthetic Oil if

necessary to maintain the oil

level in the normal (safe)

operating range (1).

3. Drive slowly at first. Select an

open area that allows room to familiarize yourself with vehicle

operation and handling.

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

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

on the daily pre-ride inspection checklist. See page 58.

6. Pull only light loads.

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

hours or 200 miles.

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OPERATION

Pre-Ride Inspection

WARNING

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

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

ensure it’s in proper operating condition.

Use the following checklist to verify that your vehicle is in proper

working condition before each use.

Item/Inspection Procedure

1. Tires - Check condition and pressures.

2. Fuel and oil tanks - Fill both tanks to their proper levels.

3. All brakes - Check operation, adjustment and fluid level (includes

auxiliary brake).

4. Throttle - Check for free operation and closing.

5. Headlight/Taillight/Brakelight - Check operation of all indicator

lights and switches.

6. Engine stop switch - Check for proper function.

7. Wheels - Check for tightness of wheel nuts and axle nuts; check

that axle nuts are secured by cotter pins.

8. Drive chain - Check condition and slack (refer to drive chain

adjustment section); lubricate when needed.

9. Air cleaner element - Check for dirt; clean or replace.

10. Steering - Check for free operation, noting any unusual looseness

in any area.

11. Loose parts - Visually inspect vehicle for any damaged components

or loose nuts/bolts or fasteners.

12. Riding gear - Wear a helmet, goggles and protective clothing.

13. Engine coolant (liquid cooled models) - Check for proper level at

the recovery bottle.

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OPERATION

Starting the Engine

Starting a Cold Engine

WARNING

Engine exhaust contains poisonous carbon monoxide and can

cause loss of consciousness resulting in severe injury or death.

Never run an engine in an enclosed area.

CAUTION

Operating the vehicle immediately after starting could cause engine

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

operating the vehicle.

1. Place the transmission in neutral

and lock the parking brake.

2. Turn the fuel tank valve on.

3. Sit on the vehicle.

4. Pull the choke knob out until it

stops (1).

NOTE: The variable choke is fully

on when the knob is pulled

completely out. The choke is off

when the knob is pushed completely in. The choke can be adjusted

gradually, depending on how much choke is needed for starting. Be

sure the choke is off during operation, as excess fuel washing into the

engine oil will increase wear on engine components.

5. Turn the engine stop switch to “run”.

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

6. 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 vehicle starts. If the engine does not start, release the

starter and wait five seconds. Then activate the starter for another

five seconds. Repeat this procedure until the engine starts.

7. If the engine slows or stops, position the choke knob half way in to

allow proper engine warm up.

8. Vary the engine RPM slightly with the throttle to aid in warm-up.

When the engine idles smoothly, push the choke all the way in.

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OPERATION

Starting the Engine

Starting a Warm Engine

Warm engines do not normally require the use of the choke. Using the

choke can cause the spark plug to become wet fouled.

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

neutral.

2. Lock the parking brake, turn the fuel tank valve to “on”, sit on the

vehicle, and turn the engine stop switch to “run”.

3. If the engine has cooled to a point where it does not readily start,

intermittent use of the choke button (pulled half way out) may be

necessary.

4. If the engine is over-choked when warm, depress the throttle lever

fully while cranking to aid in starting.

5. 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.

Cold Weather Operation for 4-Cycle Engines

If the ATV is used year-round, check the oil level frequently. A rising

oil level could indicate the accumulation of water in the bottom of the

oil tank. Water in the bottom of the tank can lead to engine damage

and must be drained. Water accumulation increases as outside

temperature decreases.

See your Polaris dealer for engine heater kits, which provide quicker

warm-ups and easier starting in colder weather.

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OPERATION

Hauling Cargo

2/3

1/3

Your ATV has been designed to carry or tow a certain amount of load.

Always read and understand the load distribution warnings listed on

the warning labels, and never exceed the weights specified in your

owner’s manual supplement.

Cargo weight should be evenly distributed (1/3 on the front and 2/3 on

the rear) and mounted as low as possible. When operating over rough

or hilly terrain, reduce speed and cargo to maintain stable driving

conditions.

Maximum Towing Capacities

Refer to your owner’s manual supplement for model specific towing

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

the amount of trailer tongue weight.

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

Belt Life

Use low forward gear when hauling or towing heavy cargo to extend

belt life.

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OPERATION

Hauling Cargo

WARNING

Hauling cargo improperly can alter vehicle handling and may cause

loss of control or brake instability and result in serious injury or

death. Always follow these precautions when hauling cargo:

S REDUCE SPEED AND ALLOW GREATER DISTANCE FOR

BRAKING WHEN HAULING CARGO.

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

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

terrain, reduce speed and cargo to maintain stable driving condi-

tions. Carrying loads on one rack only increases the possibility of

vehicle overturn.

S LOADS MUST BE CARRIED AS LOW ON THE RACKS AS

POSSIBLE. Carrying loads high on the racks raises the center of

gravity of the vehicle and creates a less stable operating condi-

tion. When cargo loads are carried high on the racks, the weight

of the loads must be reduced to maintain stable operating condi-

tions.

S ALL LOADS MUST BE SECURED BEFORE OPERATING. Un-

secured loads can create unstable operating conditions, which

could result in loss of control of the vehicle.

S OPERATE ONLY WITH STABLE AND SAFELY ARRANGED

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

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

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

vehicle.

S HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROB-

LEMS. Use extreme caution when applying brakes with a loaded

vehicle. Avoid terrain or situations that may require backing

downhill.

S EXTREME CAUTION MUST BE USED when operating with

loads extending over the rack sides. Stability and maneuverabili-

ty may be adversely affected, causing the machine to overturn.

S DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carry-

ing loads on the front rack.

S DO NOT TRAVEL FASTER THAN THE RECOMMENDED

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

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

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

while cornering, or while ascending or descending a hill.

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OPERATION

Driving Safely

Driving Procedures

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

handlebars.

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

into gear.

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

4. Release the parking brake.

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

Vehicle speed is controlled by the amount of throttle opening.

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

on level surfaces.

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OPERATION

Driving Safely

Making Turns

Some Polaris ATVs are equipped with a solid rear axle, which drives

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

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

when turning and the inside tire must slip traction slightly.

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

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

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

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

technique should be used for turning in reverse.

NOTE: Practice making turns at slow speeds before attempting to turn

at faster speeds.

WARNING

Turning at sharp angles or at excessive speeds can result in vehicle

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

Never turn at high speeds.

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OPERATION

Driving Safely

Driving on Slippery Surfaces

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

or during freezing weather, follow these precautions:

1. Slow down when entering slippery areas.

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

quick, sharp turns which can cause skids.

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

and shifting your body weight forward.

4. Driving with Demand 4 Drive(All Wheel Drive)engagedcan assistin

controlling the vehicle in slippery areas.

CAUTION

Severe damage to drive train may occur if the AWD is engaged

while the wheels are spinning.

WARNING

Failure to exercise care when operating on slippery surfaces can

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

and serious injury or death.

Never apply the brakes during a skid.

Do not operate on excessively slippery surfaces.

Always reduce speed and use additional caution.

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OPERATION

Driving Safely

Driving Uphill

Whenever traveling uphill, follow these

precautions:

1. Always travel straight uphill.

2. Avoid steep hills (25_ maximum).

3. Keep both feet on the footrests.

4. Transfer your weight forward.

5. Proceed at a steady rate of speed

and throttle opening.

6. Remain alert and be prepared to

take emergency action. This

may include quick dismounting

of the vehicle.

25_ Maximum

If all forward speed is lost:

Keep your weight uphill.

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

auxiliary brake as well, then lock the park brake.

If the ATV begins rolling backwards:

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

auxiliary rear brake while rolling backwards.

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

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

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

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

described on page 69.

WARNING

Braking and handling are greatly affected when operating in hilly

terrain. Improper procedure could cause loss of control or

overturn and result in serious injury or death.

Avoid climbing steep hills (25_ maximum).

Use extreme caution when operating on hills, and follow proper

operating procedures outlined in the owner’s manual.

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OPERATION

Driving Safely

Sidehilling

WARNING

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

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

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

as outlined in the owner’s manual.

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

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

necessary, follow these precautions:

1. Slow down.

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

while keeping your feet on the footrests.

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

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

downhill, if possible, or dismount on the uphill side immediately!

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OPERATION

Driving Safely

Driving Downhill

Whenever descending a hill, follow these precautions:

1. Proceed directly downhill.

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

3. Slow down.

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

lever.

NOTE: Familiarize yourself with operation of the auxiliary rear brake

pedal for additional braking in the event of normal service brake loss.

WARNING

Excessive speed can cause loss of control and lead to serious

injury or death. Always operate slowly when traveling downhill.

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OPERATION

Driving Safely

Turning Around on a Hill

WARNING

Improper hill climbing procedures could cause loss of control or

overturn and result in serious injury or death.

Avoid climbing steep hills (25_ maximum).

Use extreme caution when operating on hills, and follow proper

operating procedures outlined in the owner’s manual.

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

One maneuver that can be used when it’s necessary to turn around

while climbing a hill is the K-turn:

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

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

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

vehicle is pointing straight uphill.

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

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

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

pointing across the hill or slightly downward.

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

side, keeping body weight uphill.

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

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

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

8’

Uphill

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OPERATION

Driving Safely

Driving Through Water

Your ATV can operate through water

with a maximum recommended

depth equal to the bottom of

the footrests (1). Follow

these procedures when

operating through

water:

1. Determine water

depths and current

before crossing.

2. Choose a crossing

where both banks have

gradual inclines.

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

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

lever until braking action is normal.

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

outlined in the maintenance chart. See page 75. The following areas

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

gearcases, and all grease fittings.

CAUTION

Major engine damage can result if the vehicle is not thoroughly

inspected after operation in water. Perform the services outlined

in the maintenance chart.

If your vehicle becomes immersed or is operated in water that

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

before starting the engine.

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

water. If you cannot avoid water that exceeds the recommended

maximum depth, go slowly, balance your weight carefully, avoid

sudden movements, and maintain a slow and steady forward motion.

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

changes.

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

dealer before starting it, follow the steps described on page 127. Have

the vehicle serviced by your dealer at the first opportunity.

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OPERATION

Driving Safely

Driving Over Obstacles

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

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

branches.

WARNING

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

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

Travel with caution in unfamiliar terrain.

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OPERATION

Driving Safely

Driving in Reverse

Follow these precautions when operating in reverse:

1. Always avoid backing

downhill.

2. Back slowly.

3. When in reverse,

apply the brakes

lightly for stopping.

4. Avoid turning at sharp

angles in reverse.

5. Never open the throttle

suddenly while backing.

WARNING

Failure to use caution when operating in reverse can result in

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

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

proceed, back slowly.

Do not use the override switch unless additional power is required

for vehicle movement. Use with caution.

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

NOTE: Most Polaris ATVs are equipped with a reverse speed limiter.

The override button should be used with caution as rearward vehicle

speed is greatly increased. Do not operate at wide open throttle. Open

the throttle just enough to maintain a desired speed.

CAUTION

Excessive throttle operation while in the speed limit mode may

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

and/or engine damage.

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OPERATION

Driving Safely

Parking on an Incline

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

these precautions:

1. Turn the engine off.

1. Place the transmission in gear.

2. Set the parking brake.

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

illustration.

4. Shut off the fuel supply.

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NOISE EMISSION CONTROL

SYSTEM REGULATION

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED!

U.S. Federal law prohibits the following acts or the causing thereof:

(1) The removal or rendering inoperative by any person other than for

purposes of maintenance, repair, or replacement of any device or

element of design incorporated into any new vehicle for the purpose of

noise control prior to its sale or delivery to the ultimate purchaser or

while it is in use or

(2) the use of the vehicle after such device or element of design has

been removed or rendered inoperative by any person.

ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE

ACTS LISTED BELOW INCLUDE BUT ARE NOT LIMITED TO

THE FOLLOWING:

1. Removal or alteration or the puncturing of the muffler or any engine

component which conducts removal of engine exhaust gases.

2. Removal or alteration or the puncturing of any part of the engine air

induction system.

3. Replacement of any vehicle parts with parts not in compliance with

federal regulations.

4. Lack of proper maintenance.

CAUTION

Exhaust system components are very hot during and after use of

the vehicle. Hot components can cause serious burns and can

cause a fire to ignite.

Do not touch hot exhaust system components.

Use caution when traveling through tall grass, especially dry

grass.

USFS Approved Spark Arrestor

Most Polaris ATVs have mufflers that were tested and approved in

accordance with the USFS Forest Service Standard 5100-1A. Refer to

your owner’s manual supplement for model specific information.

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MAINTENANCE AND LUBRICATION

Accessories

Auxiliary power outlets provide 12V power for operating accessories

such as hand held spot lights. Accessory outlets are available for all

models. Contact your Polaris dealer for more information.

Polaris has a wide range of additional accessories available for your

ATV. See your Polaris dealer.

Periodic Maintenance Schedule

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

schedule.

Some models are equipped with a speedometer that has a

programmable service interval mode. This important feature will help

you determine when maintenance service is due. See page 54 for

instructions.

Maintenance intervals in the following charts are based upon average

riding conditions and an average vehicle speed of approximately 10

miles per hour. Vehicles subjected to severe use, such as operation in

wet or dusty areas, should be inspected and serviced more frequently.

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.

NOTE: Service and adjustments are critical. If you’re not familiar

with safe service and adjustment procedures, have a qualified dealer

perform these operations.

Maintenance Chart Key

Perform these operations more often under severe use, such as in

dirty or wet conditions, to purge water or dirt contamination from

grease fittings and other critical components.

Emission Control System Service (California - 4-Cycle)

NOTE: Some 4-Cycle models may have an additional California

-only emissions warranty. Please refer to your owner’s manual

supplement for model specific information.

Dealer service item.

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Hours of operation are based on a 10 mph average. If service is due at

20 hours, the equivalent odometer reading would be 200 miles.

Perform all services at whichever reading is reached first.

WARNING

Improperly performing the procedures marked with a J could result

in component failure and lead to serious injury or death. Have an

authorized Polaris dealer perform these services.

Item

Hours/

Miles

Frequency Remarks

Brake System

Auxiliary Brake

Tires

Pre-Ride Pre-Ride

Inspect

Wheels

Frame nuts, bolts,

fasteners

Oil level (2-Cycle)

Pre-Ride Pre-Ride

Check when refueling

Inspect; clean

Air filter,

Pre-cleaner

Coolant level

Pre-Ride Pre-Ride

Replace coolant every two

years

Fuel and oil tanks

Throttle

Pre-Ride Pre-Ride

Fill to proper levels

Check operation

Lights

Check operation

Engine stop switch Pre-Ride Pre-Ride

Check operation

Drive chain

Steering

Pre-Ride Pre-Ride

Check condition/slack

Check for free operation

Air box sediment

tube

Drain deposits whenever

visible

Headlamp

Pre-Ride Pre-Ride

Check operation daily; ap-

ply Polaris dielectric grease

to connector when replaced

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item

Hours/

Miles

Frequency Remarks

Taillight/brakelight

Pre-Ride Pre-Ride

Check operation daily; ap-

ply Polaris dielectric grease

to socket when replaced

Air filter,

main element

Weekly

Inspect; replace as needed

Transmission oil

level

20 hrs

Monthly

Inspect monthly; change

annually

Battery

Check terminals; clean;

check fluid level

Engine counterbal- 20 hrs

ance (400 Engines)

Check oil level; change

annually

Engine breather

filter (4-cycle)

20 hrs

Inspect; replace annually

and as needed

Brake pad wear

10 hrs

Monthly

Inspect periodically

Front and rear

gearcase oil (shaft

drive)

100 hrs

Check monthly; change

annually

Engine cylinder

head and cylinder

base fasteners

25 hrs

3 months

Inspect (re-torque required

at first service only)

General lubrication 50 hrs

Lubricate all fittings, pivots,

cables, etc.

Engine oil level/oil

change (4-Cycle)

100 hrs / 6 months

1000

miles

Check level daily; break-in

service at one month;

change oil more often in

cold weather

Oil Filter(4-Cycle)

100 hrs./ 6 months

1000 mi.

Replace with oil change

Oil Pump Cable

(2-Cycle)

50 hrs.

6 months

Inspect, adjust, lubricate,

replace if required

Engine breather

hose

(4-cycle)

100 hrs. 6 months

Inspect

" More often under severe use, such as dirty or wet conditions

L Emission Control System Service (California)

J Dealer service item

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

WARNING

Improperly performing the procedures marked with a J could result

in component failure and lead to serious injury or death. Have an

authorized Polaris dealer perform these services.

Item

Hours/

Miles

Frequency Remarks

Carburetor float

bowl

50 hrs.

6 months

Drain bowl periodically and

prior to storage

Throttle Cable/ETC 50 hrs.

Switch

Inspect; adjust; lubricate;

replace if necessary

Choke (enricher)

cable

50 hrs.

Inspect; adjust; lubricate;

replace if necessary

Coolant strength/

pressure test sys-

tem

100 hrs. 6 months

Inspect strength seasonal-

ly; pressure test system

annually

Front hubs/fluid

check (AWD)

50 hrs.

6 months

Check monthly

Shift linkage

Drive belt

50 hrs.

6 months

Inspect; adjust

Inspect; replace as needed

Inspect daily; lubricate

Steering

Front suspension

Inspect; lubricate; tighten

fasteners

Rear suspension

Drive chain(s)

50 hrs.

6 months

Inspect; tighten fasteners

Inspect daily; adjust and lu-

bricate if needed

Spark plug

100 hrs. 12 months Inspect; replace as needed

50 hrs. 6 months Inspect bearings; lube

100 hrs. 12 months Inspect; adjust as needed

Rear axle

Ignition Timing

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item

Hours/

Miles

Frequency Remarks

Fuel system

100

hours

12 months Check for leaks at tank

cap, lines, fuel valve, filter,

pump and carburetor; re-

place lines every two years

Fuel filter

Radiator

100 hrs. 12 months Replace annually

100 hrs. 12 months Inspect; clean external sur-

face

Cooling system

hoses

100 hrs. 12 months Inspect

Spark arrestor

100 hrs. 12 months Clean out

Front hubs (AWD)

100 hrs. 12 months Change fluid annually

Clutches (drive and 100 hrs. 12 months Inspect; clean

driven)

Engine mounts

100 hrs. 12 months Inspect

Valve clearance

(4-Cycle)

100 hrs. 12 months Inspect; adjust

Oil filter (2-Cycle)

100 hrs. 12 months Replace

Shift selector box

(H/L/R)

200 hrs. 24 months Change lubricant every two

years

Brake fluid

200 hrs. 24 months Change every two years

300 hrs. 36 months Inspect; replace as needed

Front wheel bear-

ings (2WD)

Idle speed

As required Adjust

Recoil housing

As required Drain moisture out after rid-

ing in water

Toe adjustment

Headlight aim

As required Periodic inspection; adjust

when parts are replaced

As required Adjust as needed

" More often under severe use, such as dirty or wet conditions

L Emission Control System Service (California)

J Dealer service item

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

NOTE: Hours are based on 10 mph average. If service is due at 20

hours, the equivalent odometer reading would be 200 miles. Perform

all services at whichever reading is reached first.

Lubrication Chart Key

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

L Polaris Premium All Season Grease or grease conforming to NLG

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

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

periods of storage, or after pressure washing or submerging

When suspension action becomes stiff, or after washing

∆

Item

Lube

Polaris

Method

Frequency

2-Cycle

Engine

Fill oil tank. See page 45.

As needed,

when refueling

Injection Oil

4-Cycle

Engine

Polaris Premium 4 Add to proper level on dip-

Check level daily.

Synthetic 0W40

stick.

Brakes

DOT 3 fluid only

Maintain level between fill

lines. See page 39.

As required; change

every two years or

200 hours

Drive chain(s) O-ring chain lube

or SAE 80/90

Lubricate as often as re-

quired. Before each ride in

wet conditions

As required

(1) Transmis- Polaris Premium

See Page 91.

Check every 6

sion

Synthetic gear

case lube

months/1000 miles.

Change annually or

at 100 hours

(2) Front

Gearcase

Polaris Premium

Synthetic gear

case lube

See Page 95.

Change annually or

at 100 hours

(3) Visco

Drive

Polaris Premium

Synthetic gear

case lube

Change annually or

at 100 hours

(4) Front Prop FGrease

Shaft U-joints

Grease fittings.

Every 3 months or

50 hours

(5) Front Prop FGrease

Shaft Yoke

Grease fittings (3 pumps

maximum)

Every 3 months or

50 hours

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

(1)

(2)

(3)

(2)

(4)

(5)

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Item

Lube

Method

Frequency

(6) Demand 4

Hubs - All

Wheel Drive ATVs

Premium

Hub Lube

Remove set screw in hubs. Rotate

wheels to 4 O’clock position. If lubri-

cant is not visible add more. Reinstall

set screw.

Annually or at

100 hrs.

(7) Front Drive

Axle (U Joint)

(AWD Models)

FGrease

Locate grease fitting and grease with

grease gun.

Every 3

months or 50

hours

(8) Ball Joint

Locate fitting on back side of struts

and grease with grease gun.

Every 3

months or 50

hours

Grease

(9) Counter

Balance Housing

(400)

Polaris

Check level on dipstick and add oil as Check

Premium

Synthetic

4-cycle or

SAE 10/30

necessary. Change annually.

monthly and

change

annually

(10) Rear Axle

Bearing

Locate fittings and grease

Every 3

months or 50

hours

Grease

(11) Swing Arm

Bushings

Locate fittings on swing arm and

grease with grease gun.

Monthly or at

20 hours

Grease

(12) Upper Con-

trol Arms

Locate fittings and grease

Locate fitting and grease

Semi-annually

"L∆

Grease

(13) Lower Con-

trol Arms

"L∆

Grease

(14) Rear Wheel

Hub Bearing Car-

rier

"L∆

Grease

(15) Rear Anti-

Roll Bar

Grease

Locate fitting and grease

Semi-annually

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

L Polaris Premium All Season Grease or grease conforming to NLGI No. 2, such

as Conoco Superlube M or Mobilegrease Special

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

periods of storage, or after pressure washing or submerging.

When suspension action becomes stiff, or after washing

∆

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

(7)

(6)

(9)

(8)

(6) 4 O’clock

position

(12)

(11)

(14)

(10)

(15)

(13)

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Record

Use the following chart to record periodic maintenance.

Maintenance

Interval

Performed

Servicing Servicing

Remarks

Date

Dealer

or Person

10 hrs.

20 hrs.

50 hrs.

100 hrs.

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Polaris 2-Cycle Lubricants

Polaris Premium 2-cycle lubricants are the most advanced formulation

of oils, specifically designed for today’s 2-cycle engines. Our ongoing

lab and field tests have resulted in a new generation of 2-cycle

lubricants.

Polaris Premium 2-cycle lubricants provide additives for 2-cycle

engines (lacking in today’s fuel). These necessary additives keep ring

grooves cleaner for less ring sticking and improved overall engine

cleanliness. With new generation lubricity technology, Polaris oils

excel in meeting the lubrication demands of today’s high performance

2-cycle engines. These optimum oils are recommended for liquid

cooled and air cooled 2-cycle engines.

Polaris Premium 2-cycle oils will readily mix with each other, but do

not mix Polaris Premium 2-cycle oils with any other brand of oil,

including our Nature Oil Biodegradable oil. Their incompatibility

could result in engine damage.

See page 141 for the part numbers of Polaris-recommended products.

Premium Gold Synthetic 2-Cycle Oil

Your vehicle has been primed with Premium Gold Synthetic oil. This

lubricant has been specially formulated for low smoke, low odor and

high lubricity.

Premium 2-Cycle Oil

Polaris also has a TC-W3 premium oil available for use in all of our

2-cycle products. We highly recommend its use if Premium Gold

Synthetic is not used.

CAUTION

Mixing brands or using a non-recommended oil may cause serious

engine damage. We recommend the use of Polaris Premium

2-cycle oil or Premium Gold Synthetic 2-cycle oil for your 2-Cycle

engine. Never substitute or mix oil brands.

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Premium 4 Synthetic Oil

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. NOTE: See page 141 for the

part numbers of Polaris-recommended products.

Premium 4 possesses unsurpassed film strength over the widest

possible temperature range. It resists viscosity and frictional

breakdown in ambient temperatures from -40° F. to 120° F. Its

exceptional 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 temperature operation.

CAUTION

Mixing brands or using a non-recommended oil may cause serious

engine damage. We recommend the use of Polaris Premium 4 All

Season synthetic oil or API certified “SH” oil, 0W-40. Never

substitute or mix oil brands. Use only 0W-40.

Oil and Filter Change

4-Cycle Engines With External Oil Tank

The recommended oil change interval is 100 hours, 1000 miles, or

every six months, whichever comes first.

Suggested break-in oil change is at 20 hours, 200 miles, or one month,

whichever comes first. Severe use operation requires more frequent

service. Severe use includes continuous duty in dusty or wet

conditions and cold weather riding. NOTE: Severe use cold weather

riding is all riding below 10° F., and riding between 10° F and 30°F

when most trips are slow speed and less than 5 miles.

Be sure to change the oil filter whenever changing oil

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Oil and Filter Change

4-Cycle Engines With External Oil Tank

1. Position the vehicle on a level surface.

2. Clean the area around the drain plug, which is located on either the

bottom of the oil tank or on the bottom of the engine.

3. Run the engine for two to three minutes until warm, then turn the

engine off.

CAUTION

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

oil to come into contact with skin.

4. Place a drain pan beneath the vehicle and remove the drain plug.

5. Allow the oil to drain completely.

6. Install a new sealing washer on the oil drain plug. NOTE: The

sealing surfaces on the drain plug and on the oil tank should be

clean and free of burrs, nicks or scratches.

7. Reinstall the drain plug. Torque to 14-17 ft. lbs. (19-23 Nm).

8. Disconnect the lower oil

delivery hose. Remove the

fitting (C) from the oil

tank. Clean the fitting

screen. Reinstall the fitting

screen, torquing to 14-17 ft.

lbs. (19-23 Nm). Reattach

oil line. Torque hose clamp

(E) to 25 in. lbs.

9. Place shop towels beneath

the oil filter. Using an oil

filter wrench, turn the filter

counterclockwise to

remove.

10. Using a clean, dry cloth,

clean the filter sealing

surface on the crankcase.

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Oil and Filter Change

4-Cycle Engines With External Oil Tank

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

oil. Make sure the gasket is in good condition. Also make sure the

gasket from the old filter is not still on the engine.

12. Install the new filter (1) and tighten by hand 1/2 to 3/4 turn after

the gasket contacts the engine.

13. Approximately one cup of engine oil will remain in the crankcase

sump. To drain, remove the drain plug on the lower right side of

the crankcase.

CAUTION

Loss of oil pump prime could result in engine damage. It’s extremely

important to drain, refill and start the engine in an expedient manner.

Do not allow the engine to sit without oil for extended periods.

14. Reinstall the drain plug. NOTE: The sealing surfaces on the drain

plug and crankcase should be clean and free of burrs, nicks or

scratches.

15. Remove the dipstick (2) and add the amount of oil indicated in

your owner’s manual supplement. Reinstall the dipstick. NOTE:

If the sump is not drained, add about 1 3/4 quarts initially.

16. Place the gear selector in

neutral and set the parking

brake.

17. Start the engine and let it

idle for one to two minutes.

Stop the engine and inspect

for leaks.

18. Re-check the oil level on

the dipstick and add oil as

necessary to bring the level

to the upper mark on the

dipstick.

19. Dispose of used filter and oil properly.

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Oil and Filter Change

Magnum 330 2x4, Magnum 330 4x4, Trail Boss

1. Position the vehicle on a level

surface.

2. Clean the area around the drain

plug (1).

3. Run the engine for two to three

minutes until warm. Stop the

engine.

CAUTION

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

oil to come into contact with skin.

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

drain plug.

5. Allow the oil to drain completely.

6. Install a new sealing washer on the drain plug. NOTE: The

sealing surfaces on the drain plug and crankcase should be clean

and free of burrs, nicks or scratches.

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

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

turn the filter counterclockwise to remove.

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

crankcase.

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

Check to make sure the gasket is in good condition.

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

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

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Oil and Filter Change

Magnum 330 2x4, Magnum 330 4x4, Trail Boss

12. Remove the dipstick and fill the sump with 2 quarts (1.9 l) of

Polaris Premium 4 synthetic oil.

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

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

engine and inspect for leaks.

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

the upper mark on the dipstick.

16. Dispose of used filter and oil properly.

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Transmission Oil Check - Models with Fill Plug

Scrambler 500 4x4, Magnums: 500, 330 4x4, 330 2x4

The transmission lubricant level should be checked every six months or

1000 miles (1600 km), whichever comes first. Transmission oil should

be changed annually.

1. Position the ATV on a level surface, remove the fill plug (1), and

check the oil level. NOTE: The transmission fill plug is located

on the right side of the machine, behind either the propshaft shield

or footwell.

2. Use the gearcase oil fill chart and the following illustration to

determine correct fluid levels. NOTE: When adding oil, use

Polaris Premium Synthetic Gearcase Lubricant. See page 141 for

the part numbers of Polaris-recommended products.

Gearcase Oil Fill Chart

Model

Oil Level “A” Oil Fill Ounces (ml)

Scrambler 500 4x4

Magnum 500

1 5/8″

3/4″

27 (800)

13.5 (400)

27 (800)

Magnum 330 4x4

Magnum 330 2x4

Magnum 4x4

Shown

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Transmission Oil Change - Models with Fill Plug

Scrambler 500 4x4, Magnums: 500, 330 4x4, 330 2x4

1. If equipped, remove the propshaft shield from the right side of the

vehicle to access the fill plug.

2. Remove the fill plug.

3. Remove the transmission drain plug located on the bottom left

hand side and drain the oil. Catch and discard used oil properly.

4. Clean and reinstall the drain plug torque to 14 ft. lbs. (19 Nm).

5. Add the correct amount of Polaris Premium Synthetic Gearcase

Lubricant. Refer the the gearcase oil fill chart on page 91 for

proper oil levels.

6. Check for leaks.

7. Reinstall the propshaft shield if equipped.

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Transmission Oil Check - Models with Dipstick

On most 2x4 models, the

transmission dipstick (1) is

located on the right side of the

machine. On the Sportsman, the

dipstick is located near the rear

brake disc.

The transmission lubricant level

should be checked monthly or

1000 miles (1600 km), whichever

comes first. Transmission oil

should be changed annually.

1. Position the ATV on a level surface, remove the fill plug dipstick

and wipe it clean.

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

level. Add the proper lubricant as required to bring level into the

safe operating range. NOTE: When adding oil, use Polaris

Premium Synthetic Gearcase Lubricant. See page 141 for the part

numbers of Polaris-recommended products.

Transmission Oil Change - 2x4 Models

1. Place a drain pan beneath the

transmission oil drain plug

area.

2. Loosen the jam nut (A).

3. Turn the adjuster bolt (B) in to

allow the removal of the drain

plug (C).

4. Remove the drain plug and

wipe the magnetic end clean to

remove accumulated metallic

filings.

5. After the oil has drained

completely, install a new

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

(19 Nm).

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

turn an additional 1/2 turn.

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Transmission Oil Change - 2x4 Models

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

8. Add the proper lubricant through the dipstick hole until the oil

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

9. Check for leaks.

Transmission Oil Change - Sportsman

1. Remove the fill plug/dipstick.

2. Remove the transmission drain plug and

drain the oil. Catch and discard used oil

properly.

3. Clean and reinstall the drain plug.

4. Add 32 oz. (948 ml) of Polaris Premium

Synthetic Gearcase Lubricant to the full

mark on the fill plug/dipstick. Maintain

the oil level in the safe operation range

(1). NOTE: See page 141 for the part

numbers of Polaris-recommended

products.

5. Reinstall the fill plug/dipstick and check

for leaks.

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Front Gearcase Oil Check

The front gearcase oil level should be

checked every six months or 1000

miles (1600 km), whichever comes

first. The oil should be changed

annually. Use Polaris Premium

Synthetic Gearcase Lube (or GL5

80-90 weight gear lube). NOTE: See

page 141 for the part numbers of

Polaris-recommended products.

Type A and B - With the ATV on a

level surface, remove the fill plug and

check the oil level. The level should

be maintained at the bottom of the fill

plug threads.

Type C - The lubricant level in this

type of gearcase cannot be checked.

Periodically drain the oil and refill.

Front Gearcase Oil Change

1. Position the vehicle on a level

surface and remove the fill plug

(1).

2. Place a drain pan beneath the

gearcase, remove the gearcase

drain plug, and drain the oil.

3. Clean and reinstall the drain plug.

Torque to 14 ft. lbs. (19 Nm).

4. Add the recommended gear lube

according to the following chart.

5. Reinstall the fill plug and check

for leaks.

Gearcase

Type

Capacity

4 oz. (120 ml)

13.5 oz. (400 ml )

5 oz. (150 ml)

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Rear Gearcase Oil Check

With the ATV on a level surface,

remove the fill plug and view the

oil level through the fill hole (1).

Lubricant should be kept even

with the center of the drillpoint

(2), approximately 1 5/8″ below

the top of the fill hole. Use Polaris

Premium Synthetic Gearcase

Lube (or GL5 80-90 weight gear

lube). NOTE: See page 141 for

the part numbers of

Polaris-recommended products.

NOTE: Do not add lubricant to

the bottom of the fill plug threads.

Rear Gearcase Oil Change

1. Remove the drain plug (3).

Catch and discard used oil

properly.

2. Clean and reinstall the drain

plug with a new sealing

washer. Torque to 14 ft. lbs.

(19 Nm).

1 5/8″

3. Remove the fill plug and add

10 oz. (300 ml) of the

recommended gear lube.

Maintain the oil level even

with the center of the

drillpoint (approximately 1

5/8″ below the top of the fill

hole).

4. Reinstall the fill plug. Torque to 14 ft. lbs. (19 Nm).

5. Check for leaks.

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Counter Balance Oil Check - 400 2-Cycle Engines

The counter balance oil should be checked semi-annually and oil

should be added or changed as needed. The oil should be changed

annually and before off season storage. If the machine is used in wet

conditions, check the oil more frequently. NOTE: If the oil has a

milky appearance it should be changed as soon as possible.

Failure to properly maintain the counter

balance lubrication can result in

premature wear or possible failure of the

counter balance components. Always

use SAE 10W30 oil.

1. Remove the seat and remove the

dipstick (1).

2. Read the oil level. If necessary, add

SAE 10W30 oil with a transmission

fluid funnel until the oil reaches the

recommended level on the dipstick

(2). NOTE: If overfilled, the

excess oil will be expelled through

the vent hose.

3. Reinstall the dipstick and reinstall

the seat.

Counterbalance Oil Change - 400 2-Cycle Engines

Drain Locations

A Counter Balance Drain

B Crankcase Drain

C Recoil Drain

D Starter Pinion Drain

1. Remove the skid plate and remove

the counter balance drain plug (A).

Catch used oil and discard of

properly.

2. Clean and reinstall the drain plug.

3. Add 10W30 oil to the full mark on

the dipstick. Capacity after draining is approximately 2.3 - 2.5 oz.

(70-75 cc).

4. Reinstall the dipstick and check for leaks.

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Engine Oil Check

The oil tank is located either on the left side of the vehicle (external

tank models)(1) or on the engine (2).

1. Position the machine on a level surface.

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

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

4. Screw the dipstick completely in. NOTE: The dipstick must be

screwed completely in to keep the angle and depth of the stick

consistent.

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

the normal (safe) operating range (3). Do not overfill.

ADD 8 OZ.

NORMAL

FULL

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MAINTENANCE AND LUBRICATION

Engine Cooling System

Coolant Level

The recovery bottle (1) is located on

the left side of the machine. To

access the recovery bottle on Gen

IV machines, remove the left side

panel. See page 111.

GEN III

The fluid level must be maintained

between the minimum and

maximum marks on the bottle

(when the fluid is cool).

The engine coolant level is

controlled or maintained by the

recovery system. The recovery

system components are the recovery

bottle, radiator filler neck, radiator

pressure cap and connecting hose.

GEN IV

As coolant operating temperature

increases, the expanding (heated)

excess coolant is forced out of the

radiator, past the pressure cap, and

into the recovery bottle. As engine

coolant temperature decreases, the

contracting (cooled) coolant is

drawn back up from the tank, past

the pressure cap, and into the

radiator.

NOTE: Some coolant level drop on new machines is normal, as the

system is purging itself of trapped air. Observe coolant levels and

maintain as recommended by adding coolant to the recovery bottle.

Polaris recommends the use of Polaris Premium 60/40

anti-freeze/coolant or a 50/50 mixture of high quality aluminum

compatible anti-freeze/coolant and distilled water. See page 141 for the

part numbers of Polaris-recommended products.

NOTE: Polaris Premium 60/40 is already premixed and ready to use.

Do not dilute with water.

NOTE: Always follow the manufacturer’s mixing recommendations

for the freeze protection required in your area.

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MAINTENANCE AND LUBRICATION

Engine Cooling System

WARNING

Escaping steam can cause severe burns. Never remove the

pressure cap while the engine is warm or hot. Always allow the

engine to cool before removing the pressure cap.

Radiator Coolant Level

NOTE: This procedure is required

GEN III

only if the cooling system has been

drained for maintenance and/or repair.

However, if the recovery bottle has

run dry, the level in the radiator

should be inspected and coolant

added if necessary.

1. Locate the radiator pressure cap:

Gen III - Clean the area around the

oil cap (1) and remove it (2-cycle

models). Remove the front cover by

placing your fingers under the front

of the cover and pulling upward.

Reinstall the oil cap.

GEN IV

Gen IV - Using the tool provided,

remove the four screws securing the

front rack (2). Remove the front

cover (3) by placing your fingers

under the front of the cover and

pulling upward.

2. Remove the pressure cap.

3. Using a funnel, slowly add

coolant as necessary through the

radiator filler neck.

4. Replace the pressure cap and

secure the front cover.

NOTE: Use of a non-standard pressure cap will not allow the

recovery system to function properly. Contact your dealer for the

correct replacement part.

100

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MAINTENANCE AND LUBRICATION

Engine Cooling System

NOTE: To ensure that the coolant maintains its ability to protect the

engine, we recommend that the system be completely drained every

two years and a fresh mixture of antifreeze and water added. Polaris

recommends the use of Polaris Premium 60/40 anti-freeze/coolant 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 141 for the part

numbers of Polaris-recommended products.

NOTE: Always follow the manufacturer’s mixing recommendations

for the freeze protection required in your area.

Oil Pump Bleeding - 2-Cycle Engines

1. Fill the oil reservoir with Polaris Premium 2-Cycle Oil. NOTE:

See page 141 for the part numbers of Polaris-recommended

products.

2. If the oil supply line has been disconnected from the pump, or if

the oil reservoir and supply line have been completely run out of

oil, loosen the bleeder screw one full turn (skip this step if

conditions do not apply). Allow oil to flow from the bleed screw

for five to ten seconds, then tighten the bleed screw.

CAUTION

Allowing the engine to run while the bleed screw is loose will result

in loss of oil, which will cause serious engine damage. Always

retighten the bleed screw if it’s been loosened for service.

3. Start the engine and rotate the oil pump lever to its full open

position. With the engine at idle, hold the lever up for thirty

seconds to purge all air from the system.

101

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MAINTENANCE AND LUBRICATION

Adjustments

Oil Pump - 250 Engines

1. Before adjusting the oil pump, check the

engine idle RPM and carburetor settings

in the owner’s manual supplement.

2. Loosen throttle cable jam nut and turn

the adjuster (1) in or out until there is

1/16″ - 1/8″ (.16 - .32 cm) of throttle

lever travel before the throttle slide starts

to open. See your owner’s manual

supplement.

3. Place very slight pressure on the throttle

lever (2) until all freeplay is removed

from the throttle cable (to the point

where the carb slide is just starting to

rise).

4. Loosen the locknut (3).

Turn the adjuster in or out

until all freeplay is removed

from the oil pump cable (the

point where the oil pump

arm is just starting to move

off its stop). The pump stop

keeps the pump arm from

rotating any further down

than the idle position so no

visual alignment of marks is

necessary. Tighten the

locknut.

102

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MAINTENANCE AND LUBRICATION

Adjustments

Oil Pump - 400 Engines

1. Before adjusting the oil pump, check engine idle RPM and

carburetor adjustments in your owner’s manual supplement.

2. Loosen the throttle cable jam nut and turn the adjuster in or out

until there is 1/16″ - 1/8″ (.16 - .32 cm) throttle lever travel before

the throttle slide starts to open. See your owner’s manual

supplement.

3. Place very slight pressure on the throttle lever until all freeplay is

removed from the throttle cable (to the point where the carb slide is

just starting to rise).

4. Lift the boot (1) up off the adjuster sleeve (2).

5. Remove the oil pump cover and loosen the cable adjuster locknut.

6. Adjust the oil pump cable until

the marks align (3) when the

throttle slide just begins to rise.

7. Tighten the locknut.

8. Recheck the adjustment. If it’s

correct, slide the boot all the way

down over the upper portion of

the bottom nut (4) to ensure good

sealing against water entry.

9. Reinstall the oil pump cover and gasket.

103

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MAINTENANCE AND LUBRICATION

Adjustments

Front Brake

WARNING

After opening a bottle of brake fluid, always discard any

unused portion. Never store or use a partial bottle. Brake

fluid is hygroscopic, meaning it rapidly absorbs moisture from

the air. The moisture causes the boiling temperature of the

brake fluid to drop, which can lead to early brake fade and the

possibility of accident or severe injury.

The front brakes are hydraulic disc brakes. They’re activated by

moving the brake lever toward the handlebar. These brakes are

self-adjusting.

The following checks are recommended to keep the brake system in

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

under normal operation.

1. Always keep brake fluid at an adequate level (see page 39).

NOTE: Under normal functioning the diaphragm extends into the

reservoir as fluid level drops. If the fluid level is low and the

diaphragm is not extended, a leak is likely and the diaphragm

should be replaced. Always fill the reservoir as needed whenever

the cover is loosened or removed to ensure proper diaphragm

operation. Use Polaris DOT 3 brake fluid (see page 141).

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.

5. Check the security and surface

condition of the disc.

NOTE: Pads should be changed when

3/64″ (.1 cm)

worn to 3/64″ (.1 cm), or about the

thickness of a U.S. dime.

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Adjustments

Rear Brake

The rear brake is a hydraulic disc

brake. The rear brake system is

self-adjusting and requires no

maintenance other than periodic

checks of the pads for wear.

Pads should be changed when worn to

3/64″ (.1 cm), which is about the

thickness of a U.S. dime.

Inspect the brake disc spline and pad

wear surface for excessive wear.

3/64″ (.1 cm)

Auxiliary Brake

Your vehicle’s auxiliary brake system is intended to be used as a

backup for the main brake system. Should the main system fail, the

rear brake can be activated by depressing the foot pedal on the inside of

the right footrest. The hydraulic auxiliary brake system will not need

adjustment.

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

all-wheel single lever system.

105

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Adjustments

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.

Toe Alignment

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

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

1. Set the handlebars in a

straight-ahead position.

NOTE: The steering frog

can be used as an indicator

of whether the handlebars are

straight. The frog should

always point straight back

from the steering post.

2. Place stands (1) in front of

the vehicle, perpendicular to

the rear tires. See

illustration.

3. Tie an elastic string around

the stands, making sure the

string just touches the side

surface of the rear tires on

each side of the vehicle and

goes around the stands in

front of the vehicle (2).

4. Measure the distance from

the string to the rim at the

front and rear of the front

rim (3). Rear measurement should be 1/16″ - 1/8″ (.2 to .3 cm)

more than the front measurement.

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

for service.

106

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Adjustments

Steering Assembly

The steering assembly of the ATV should be checked periodically for

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

dealer for service before operating the vehicle.

Camber and Caster

The camber and caster are non-adjustable.

Rear Spring

The rear shock absorber spring is adjusted by rotating the adjuster (1)

either clockwise or counterclockwise to increase or decrease spring

tension.

NOTE: Accessory springs are available through your Polaris dealer.

107

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Adjustments

WARNING

Improper adjustment of the handlebars or incorrect torquing of

the adjuster block tightening bolts can cause limited steering or

loosening of the handlebars, resulting in loss of control and

possible serious personal injury or death. Follow the adjustment

procedures exactly, or see your Polaris dealer for service.

Handlebars

The handlebars can be adjusted for

rider preference.

1. Locate handlebar bolts (1). On

models with a headlight pod,

remove the upper headlight

pod. On other models, remove

the handlebar cover.

2. Loosen the four bolts.

3. Adjust the handlebar to the

desired height. Be sure the

handlebars do not contact the

gas tank or any other part of the

machine when turned fully to

the left or right.

4. Torque the front two bolts to

10-12 ft. lbs. (14-17 Nm), then

torque the rear two bolts. A gap

of up to 1/8” will remain at the

rear bolts.

108

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Adjustments

Carburetor

IMPORTANT: Your Polaris ATV is calibrated at the factory for

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

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

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

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

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

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

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

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

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

NOTE: Continuous operation of the engine without proper jetting

when required can cause poor performance, overheating or engine

damage. See your Polaris dealer for more information about jetting the

ATV for conditions in your area.

2-Cycle Engines

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

favorable, the carburetor can be adjusted.

1. Warm up the engine by running the

vehicle for approximately five

minutes.

2. Place the transmission in gear with the

parking brake applied.

3. Adjust the carburetor idle screw (1)

either in or out until the desired idle

RPM is reached. Turning the screw

in (clockwise) will raise RPM.

Turning the screw out

(counterclockwise) will lower

RPM.

The following variations apply to air screw (2) adjustment for 2-cycle

engines:

S For improving cold weather start and reducing audible detonation

noise, the air screw can be closed from 1/2 to 1 turn by turning the

screw clockwise.

S During hot weather and/or high altitude operation the air screw can

be adjusted for smoother operation by turning the screw counter-

clockwise for approximately 2 turns.

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Adjustments

Carburetor

4-Cycle Engines

If the engine idle speed is not satisfactory,

and all other conditions are favorable, the

carburetor can be adjusted.

1. Warm up the engine by running the

vehicle for approximately five

minutes.

2. Place the transmission in gear with

the parking brake applied.

3. Adjust the carburetor idle screw (1)

either in or out until the desired idle

RPM is reached. Turning the screw

in (clockwise) will raise RPM.

Turning the screw out (counterclockwise) will lower RPM.

Throttle Cable Freeplay

Throttle cable freeplay is adjusted at the handlebar.

1. Slide the boots (1) off the inline cable adjuster sleeve (2). Loosen

the adjuster locknut (3).

2. Turn the adjuster until 1/16″ to 1/8″ freeplay is achieved at the

thumb lever. NOTE: While adjusting freeplay, be sure to flip the

throttle lever back and forth.

3. Tighten the locknut and slide the boots over the cable adjuster until

they touch at the midpoint of the adjuster.

110

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Adjustments

Side Panel Removal - Gen IV

NOTE: Side panel removal may be difficult until the locking tabs and

receivers have been snapped and unsnapped a few times.

1. Remove the seat.

Step 2

2. Grasp the rear of the side

panel near the rear cab. With

a quick and firm motion, pull

the panel forward and outward

to disengage the two rear tabs.

3. Place your hand on top of the

side panel behind the fuel

tank. With a quick and firm

motion, push down on the side

panel to disengage the top rear

two tabs. Then pull up on the

side panel to disengage the

front upper and lower tabs.

Step 3

4. To reinstall the side panel,

align the panel tabs with the

slots on the front cab. Push

the panel upward and forward

until the tabs lock. Bend the

rear of the side panel and

insert the two tabs into the rear

cab.

Step 4

111

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Adjustments

WARNING

Operating your ATV with worn tires, improperly inflated tires,

non-standard tires or improperly installed tires will affect vehicle

handling and could cause an accident resulting in serious injury

or death.

Maintain proper tire pressure as described on the decal on your

ATV and in your owner’s manual supplement.

Always use original equipment size and type when replacing

tires.

Make sure the wheels are installed properly.

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

or less.

Wheel Removal

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

parking brake.

2. Loosen the wheel nuts slightly.

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

footrest frame.

4. Remove the wheel nuts and remove the wheel.

112

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MAINTENANCE AND LUBRICATION

Adjustments

Wheel Installation

1. Place the transmission in gear

and lock the parking brake.

2. Place the wheel on the wheel

hub with the valve stem toward

the outside and rotation arrows

on the tire pointing toward

forward rotation.

3. Install the wheel nuts and finger

tighten.

4. Lower the vehicle to the ground.

5. Torque the wheel nuts according to the wheel nut torque

specifications chart.

NOTE: All nuts that have a cotter pin installed must be serviced by an

authorized Polaris dealer.

Wheel Nut Torque Specifications

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

loosened for maintenance service.

Bolt Size

Front 3/8″

Rear 3/8″

Rear 1/2″

Specification

20 ft. lbs. (27 Nm)

50 ft. lbs. (68 Nm)

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Adjustments

Front Wheel Hub Tightening

Front wheel bearing tightness and spindle nut retention are critical

component operations. All service must be performed by your

authorized Polaris dealer.

Tire Tread Depth

Always replace tires when tread

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

See illustration.

1/8I (.3 cm)

WARNING

Operating the vehicle with worn tires will increase the possibility of

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

death. Always replace tires when the tread depth measures 1/8″

(.3 cm) or less.

WARNING

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

may adversely affect vehicle maneuverability and cause loss of

control resulting in serious injury or death. Maintain proper tire

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

tire always use original equipment size and type.

114

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MAINTENANCE AND LUBRICATION

Adjustments

Drive Chain

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

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

be lubricated.

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

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

slack adjustment. Maintain the stone guard to rear sprocket clearance

at 1/8″ (.3 cm).

Regularly lubricate the drive chain with SAE 80-90 lube or an

approved o-ring chain spray lube. See page 141 for the part numbers of

Polaris-recommended products.

CAUTION

Washing the drive chain with a high pressure washer or

gasoline can cause damage to the o-rings, causing premature

wear and drive chain failure. Don’t use a high pressure washer

or gasoline to clean the drive chain.

Cylinder Head/Cylinder Base Fastener - 2-Cycle

Have your dealer check the ATV cylinder head and cylinder base

fasteners for proper torque at the first service or after 25 hours.

115

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MAINTENANCE AND LUBRICATION

Adjustments

Rear Drive Chain Slack - Concentric Drive Models

CAUTION

Adjusting or operating the ATV with improper rear drive chain

slack can result in severe damage to the transmission and drive

components. Always make sure the slack is within the stated

specifications.

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

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

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

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

deflection. Use the following procedure if adjustment is required.

3/16″-3/8″ (.48 cm - .95 cm)

1. Remove the chain guard if

applicable.

2. Loosen the chain guide.

3. Loosen the two eccentric

locking bolts (1).

4. Loosen the caliper mounting

bracket bolts located under

the axle.

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

eccentric housing.

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Adjustments

Rear Drive Chain Slack - Concentric Drive Models

6. Roll the ATV forward or backward

to adjust the chain slack to the

proper tension. See the illustration

for proper splice link clip opening

position (1).

7. Tighten the eccentric locking bolts

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

without the hitch and 45 ft. lbs. (61

Nm) for machines with a hitch.

8. Tighten the caliper mount bolts to 10-12 ft. lbs. (14-17 Nm)

9. Remove the pin punch.

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

around the chain. NOTE: The chain is adjusted correctly when the

tightest portion of the chain has approximately 3/8” (10mm)

deflection.

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

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

12. Reinstall the chain guard if applicable.

117

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MAINTENANCE AND LUBRICATION

Filter Systems

Air Filter Removal and Service - 2-Cycle Engines

1. Remove the ATV seat.

2. Release the clips securing the cover assembly to the air box.

3. Loosen the clamp securing the filter, and remove the filter.

4. Remove the foam pre-filter from the main filter.

5. Wash the pre-filter in soapy water, then rinse and let dry.

6. Re-install the pre-filter over the main filter. (Replace the main filter

if needed.)

Air Filter Installation - 2-Cycle Engines

1. Check the condition of the air box and replace if necessary.

2. Replace the filter over the carburetor boot. Make sure the filter is

fully seated in the air box.

3. Tighten the clamp. Do not overtighten, as filter damage could

occur.

4. Check the cover gasket and replace if needed. Be sure the cover is

seated properly, then snap the clips onto the cover.

5. Reinstall the ATV seat.

Air Filter Cleaning - 2-Cycle Engines

NOTE: Always replace the main filter when it becomes dirty. In an

emergency situation, however, you may clean the main filter if you

observe the following practices.

1. Never immerse the main filter in water. Dirt can be transferred to

the clean air side of the filter.

2. If compressed air is used for cleaning, never exceed a pressure of

40 PSI. Always use a dispersion-type nozzle to prevent filter

damage, and blow the air from the inside to the outside.

NOTE: Replace the air filter every 50 hours and more often when the

vehicle is operated in very dirty conditions.

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MAINTENANCE AND LUBRICATION

Filter Systems

Air Filter Service - 4-Cycle

1. Remove the seat, release the clips,

and remove the air box cover.

2. Loosen the clamp and remove the

filter.

3. Remove the fabric type pre-filter

(1) from the main filter (2). Wash

the pre-filter in soapy water, then

rinse and let dry.

4. Reinstall the pre-filter over the

main filter. (Replace the main filter

if needed.)

5. Reinstall the filter into the air box

and tighten the clamp. Do not over

tighten the clamp, as filter damage

could occur.

Breather Filter/Hose - 4-Cycle Engines with Dry Sump

NOTE: Refer to your owner’s manual supplement to determine if

your machine has a dry sump.

CAUTION

Operation of your vehicle without a breather filter can cause

engine damage. Always reinstall the breather filter after

removing for service.

1. Remove the clamps and pull the filter

(1) out of the hoses. NOTE: It’s not

necessary to remove the lower hose

from the engine.

2. Inspect the filter for debris. Blow

gently through the filter in the direction

of the arrow to check for clogging.

Replace if needed.

3. Check the hoses for cracks,

deterioration, abrasion, or leaks. Replace as needed.

4. Reinstall the filter with the arrow pointing toward engine, and

secure the clamps.

119

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MAINTENANCE AND LUBRICATION

Lights

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

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

will shorten the life of the lamp.

WARNING

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

Headlight and taillight lenses become dirty during normal operation.

Wash the headlights frequently to maintain lighting quality.

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

the headlamps until they’ve cooled sufficiently.

Headlight Lamp Replacement - Scrambler

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

2. Grasp the bulb housing and turn it counterclockwise to remove the

bulb.

3. Apply dielectric grease to the light bulb socket before installing the

new bulb. Install the replacement bulb into headlight housing and

rotate clockwise firmly. NOTE: The bulb must be positioned so

the harness installs into the lamp at the bottom.

4. Reinstall the connector to the back of the headlight..

High Beam Adjustment - Scrambler

The headlight beam can be adjusted vertically.

1. Position the ATV on a level surface with the headlight

approximately 25 ft. (7.6 m) from a flat wall.

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 and 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 aimed 2” (5.1 cm) below the mark

placed on the wall. NOTE: Include rider weight on the seat when

measuring.

5. Loosen the pivot bolt and adjust the beam to the desired position.

6. Tighten the bolt and torque to 60 in. lbs.

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MAINTENANCE AND LUBRICATION

Lights

Headlight Lamp Replacement - Trail Blazer

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

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

retention screw.

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

bulb from the housing.

4. Apply dielectric grease to the light bulb socket before installing the

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

retention screw. Reinstall the rubber cap.

5. Reconnect the light harness and reinstall the cover.

6. Adjust the headlight aim if necessary.

Headlight Adjustment - Trail Blazer

1. Position the vehicle on

a level surface with the

headlight approximately

25 ft. (7.6 m) from a

flat wall.

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 and

turn on the headlight.

4. Observe the headlight

aim on the wall. The most intense part of the headlight beam

should be aimed 8” (20.3 cm) below the mark placed on the wall.

NOTE: Include rider weight on the seat when measuring.

5. Adjust the beam to the desired position by turning the adjustment

screws (1):

S Turning the right screw clockwise moves the intense spot of light up

and to the left.

S Turning the left screw clockwise moves the intense spot of the light

up and to the right.

S Turning the bottom screw clockwise adjusts the light upward.

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Lights

Headlight Lamp Replacement - Gen IV

1. Remove the three screws on the headlight pod.

2. Using a small flat-blade screwdriver, push in on the lock tabs

through the two small openings at the front of the headlight pod.

3. Lift the pod slightly while depressing the tabs.

4. Lift the pod cover and disconnect the speedometer harnesses from

the speedometer. Unplug the indicator light harness and remove

the pod cover.

5. Unplug the headlamp from the wiring harness. Be sure to pull on

the connector, not on the wiring.

6. Grasp the bulb housing and turn counterclockwise to remove lamp.

7. Apply dielectric grease to the light bulb socket before installing the

new bulb.

8. Reverse the previous steps to replace the lamp and reassemble the

pod.

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Lights

High Beam Adjustment - Gen IV

The headlight beam can be adjusted to any position desired by turning

the adjusting knob on the bottom right side of the headlight pod.

1. Position the vehicle on a level surface with the headlight

approximately 25 ft. (7.6 m.) from a wall.

2. Remove the two screws on the lower front corners of the headlight

pod.

3. Using a small flat-blade screwdriver, push in on the lock tab

through the two small openings at the front of the headlight pod.

4. Lift the pod slightly while depressing the tabs.

5. Remove the screw in the back of the headlight pod.

6. Measure the distance from the floor to the center of the headlight

and make a mark on the wall at the same height.

7. Start the engine and turn the headlight switch to high beam.

8. Observe the headlight aim on the wall. The most intense part of

the headlight beam should be aimed two inches (5.1 cm) below the

mark placed on the wall. NOTE: Include rider weight on the seat

when measuring.

9. Adjust the beam to the desired position by turning the adjustment

knob either clockwise or counterclockwise.

10. Reinstall the pod.

Snap pins

into tabs

Position

Slip o-ring

over pin

knob in

slot and

Route plug

over handlebar

secure in

locking

tabs

Adjustment

Knob Stop

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Lights

Headlight Housing Replacement - Gen IV

1. Remove the three screws on the headlight pod.

2. Using a small flat-blade screwdriver, push in on the lock tabs

through the two small openings at the front of the headlight pod.

Lift the pod lightly while depressing the tabs.

3. Lift the pod cover. Disconnect the

speedometer harnesses from the

speedometer. Unplug the indicator

light harness and remove the pod

cover.

4. Unplug the headlamp from the

wiring harness.

5. Remove the o-ring (1) from the

headlight pivot pins.

6. Pull the headlight housing up to

release from the locking tabs.

7. Lift the adjusting knob up to remove

5 1/8″

(13 cm)

from the locking tabs.

8. Carefully pull the assembly up and

out of pod.

9. Reverse the steps to install the new housing and reassemble the

pod.

NOTE: The distance from the headlamp parting line to the end of the

adjustment knob stop is 5 1/8″ (13 cm). See illustration.

10. Adjust the headlight aim by turning the adjusting knob.

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MAINTENANCE AND LUBRICATION

Lights

Taillight/Brakelight Lamp Replacement

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

replaced.

1. Remove the taillight lens cover

mounting screws. Remove the

lens cover and gasket and set

aside for reassembly.

2. Remove the lamp (1) and

replace it with a new lamp.

3. Test the taillight/brakelight to

see that it’s working.

4. Reinstall the gasket and lens cover.

Indicator Lamp Replacement

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

the indicator panel.

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

1/4 turn counterclockwise.

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

indicator panel housing.

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

5. Reassemble the pod or front cover.

125

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MAINTENANCE AND LUBRICATION

Spark Plugs

Refer to your owner’s manual supplement for recommended spark plug

and gap specifications.

CAUTION

Using non-recommended spark plugs can result in serious engine

damage. Always use Polaris-recommended spark plugs.

Spark plug condition is indicative of engine operation. The spark plug

firing end condition should be read after the engine has been warmed

up and the vehicle has been driven at higher speeds. Immediately

check the spark plug for correct color.

WARNING

A hot exhaust system and engine can cause serious burns. Wear

protective gloves when removing a spark plug for inspection.

1. Normal

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

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

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

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

overheating, caused by use of an improper spark plug or incorrect

carburetion adjustments.

2. Wet Fouled

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

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

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

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

incorrect carburetion adjustments.

Spark Plug Removal and Replacement

1. Remove the spark plug cap.

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

spark plug counterclockwise to remove.

3. Reverse the procedure for spark plug installation. Torque to 14 ft.

lbs. (19 Nm).

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MAINTENANCE AND LUBRICATION

Vehicle Immersion

CAUTION

If your vehicle becomes immersed, major engine damage can

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

to your dealer before starting the engine.

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

the steps outlined below.

1. Move the ATV to dry land or at the

very least, to water below the foot

rests.

2. Check the airbox for any water and

dry it if water is present.

3. Turn the fuel valve off.

4. Remove the spark plug.

5. Loosen the carburetor drain screw (1)

or remove the bowl drain (2).

6. For two cycle engines, remove the

crankcase drain screw. See page 97 for

the location.

7. Turn the engine over several times

using the electric start.

8. Dry the spark plug and reinstall, or

replace it with a new plug.

9. Tighten the carburetor drain screw (1)

or reinstall the bowl drain (2).

10. For two cycle engines, reinstall the

crankcase drain screw.

11. Turn the fuel valve on.

12. Attempt to start the engine. If

necessary, repeat the drying

procedure.

13. Take the ATV to your dealer for

service as soon as possible, whether

you succeed in starting it or not.

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

on page 132 for drying out the PVT.

127

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MAINTENANCE AND LUBRICATION

Spark Arrestor

WARNING

Failure to heed the following warnings while servicing the spark

arrestor could result in serious injury or death.

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

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

components to cool sufficiently before proceeding.

Remove any combustible materials from the area.

Wear eye protection.

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

Never run the engine in an enclosed area. Exhaust contains

poisonous carbon monoxide gas.

Never go under the vehicle while it’s inclined.

128

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MAINTENANCE AND LUBRICATION

Spark Arrestor

1. Remove the arrestor clean-out plug(s) (1) from the bottom of the

muffler.

2. Place the transmission in neutral and start the engine.

3. Purge carbon from the system by momentarily revving the engine

several times.

4. If carbon is expelled, cover the exhaust outlet and rap on the pipe

around the cleanout plug while revving the engine several more

times.

5. If particles are still suspected to be in the muffler, back the vehicle

onto an incline so the rear of the vehicle is one foot higher than the

front. Set the parking brake and block the wheels. Make sure the

vehicle is in neutral and repeat steps 3 and 4.

6. If particles are still suspected to be in the muffler, drive the vehicle

onto the incline so the front of the vehicle is one foot higher than

the rear. Set the parking brake and block the wheels. Make sure

the vehicle is in neutral and repeat steps 3 and 4.

7. Repeat steps 3 through 6 until no more particles are expelled when

the engine is revved.

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

arrestor plug.

129

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MAINTENANCE AND LUBRICATION

Recoil Housing

To prevent possible engine damage, always drain the recoil housing

after operating the ATV in very wet conditions. This should also be

done before storing the ATV.

Water will enter the recoil housing if the starter handle is disengaged

from the rope guide when under water. NOTE: On the Trail Blazer

250, the recoil handle must be behind the heat shield for it to seal

properly.

The drain screw is located at the bottom of the recoil housing. Use a

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

draining the housing.

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

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

crankcase drain is opened.

Drain Locations

Illustration 1 - 250 and 400 Engines

Illustration 2 - 4-Cycle Engines

A - Counter Balance Drain (400’s)

B - Crankcase Drain

C - Recoil Drain (above front prop shaft on shaft drive models)

D - Starter Pinion Drain

130

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MAINTENANCE AND LUBRICATION

PVT System

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

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

force exerted on the movable drive sheave by the flyweights also

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

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

centrifugal force decreases, reducing the amount of belt “pinch.”

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, due to the system’s

dependence on engine speed.

For example, when operating at a ground speed of 3 MPH 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, 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 and causes outer clutch covers to fail.

By switching to low range while operating at low ground speeds, the

air temperature in the clutch cover is reduced by almost 160 degrees.

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

PVT components (belt, cover, etc.).

NOTE: Models without a low range should avoid heavy pulling and

extended low-speed operation.

When To Use Low Range vs. High Range

Following is a guideline for when to use low range and high range.

Low Range

S When basic operation is at speeds less than 7 MPH

S For heavy pulling

S When operating in rough terrain (swamps, mountains, etc.) at low

ground speeds

High Range

S When basic operation is at speeds greater than 7 MPH

S When operating at high ground speeds

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MAINTENANCE AND LUBRICATION

PVT System

WARNING

Failure to comply with the instructions in this warning can result

in severe injury or death.

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

reduce its strength so that a failure may occur at a high speed.

The PVT system has been precision balanced. Any modification

will cause the system to be out of balance, creating vibration and

additional loads on components.

The PVT system rotates at high speeds, creating large amounts

of force on clutch components. Extensive engineering and

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

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

make sure this system remains safe:

Always follow all recommended maintenance procedures. See

your dealer as outlined in the owner’s manual.

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

not install it in any other product.

Always make sure the PVT housing is securely in place during

operation.

PVT Drying

There may be some instances when water is accidently ingested into

the PVT system. Use the following instructions to dry it out before

operating:

1. Remove the drain plug and allow the water to drain. Replace the

drain plug.

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

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

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

than 10 seconds.

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

transmission to the lowest available range.

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

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

132

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MAINTENANCE AND LUBRICATION

Battery (Conventional)

Keep the battery terminals and connections free of corrosion. If

cleaning is necessary, remove the corrosion with a stiff wire brush.

Wash with a solution of one tablespoon baking soda and one cup water.

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

terminals with dielectric grease or petroleum jelly.

Be careful not to allow cleaning solution or tap water into the battery.

WARNING

Battery electrolyte is poisonous. It contains sulfuric acid. Serious

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

Antidote:

External: Flush with water.

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

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

immediately.

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

attention.

Batteries produce explosive gases. Keep sparks, flame,

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

enclosed space. Always shield eyes when working near batteries.

KEEP OUT OF REACH OF CHILDREN.

133

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MAINTENANCE AND LUBRICATION

Battery

Replenishing Battery Fluid (Conventional Battery)

A poorly maintained battery will

deteriorate rapidly. Check the battery

fluid level often. The fluid level should

be kept between the upper and lower

level marks (1).

To refill use only distilled water. Tap

water contains minerals that are harmful

to a battery.

WARNING

Improperly connecting or disconnecting battery cables can result

in an explosion and cause serious injury or death. When removing

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

When reinstalling the battery, always connect the negative (black)

cable last.

Battery Removal

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

remove battery cover.

2. Remove the battery vent tube from the battery.

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

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

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

battery sideways, which could spill electrolyte.

CAUTION

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

tablespoon baking soda and one cup water to prevent damage to

the vehicle.

134

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MAINTENANCE AND LUBRICATION

Battery

Battery Installation

1. Set the battery in the battery holder.

2. With conventional batteries, install the battery vent tube. Sealed

batteries do not have a vent tube. NOTE: The vent tube must be

free of obstructions and securely installed. If not, battery gases

could accumulate and cause an explosion. The tube should be

routed away from the frame and body to prevent corrosion. Avoid

skin contact with electrolyte, which can cause severe burns.

3. First connect and tighten the red (positive) cable.

4. Second connect and tighten the black (negative) cable.

5. Reinstall the battery cover and attach the hold-down strap.

6. Verify that cables are properly routed.

NOTE: When installing a new battery, make sure it’s fully charged

prior to its initial use. Using a new battery that has not been fully

charged can damage the battery and result in a shorter life. It can also

hinder vehicle performance.

Battery Storage

When the vehicle is placed in storage for three months or more, the

battery should be removed, stored out of the sun in a cool, dry place

and tested monthly. Before reusing, take the battery to your dealer for

testing and recharging.

Power plug leads may need to be bent down so that the battery cover

can be installed.

Battery Charging (Sealed Battery)

The following battery charging instructions apply only to the

installation of a YUASA activated, sealed battery. Read all

instructions before proceeding with the installation of this battery.

The YUASA activated, sealed battery is already filled with electrolyte

and has been sealed and fully charged at the factory. Do not ever pry

the sealing strip off or add any other fluid to this battery.

The single most important thing to 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.

135

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MAINTENANCE AND LUBRICATION

Battery

Battery Charging (Sealed Battery)

For a refresh charge, follow all instructions carefully.

1. Check the battery voltage with a voltmeter or multimeter. A fully

charged battery will register 12.8 V or higher.

2. If the voltage is less than 12.8 volts, recharge the battery.

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

manufacturer’s instructions for recharging. When using a constant

current charger, use the following guidelines for recharging.

WARNING

An overheated battery could explode, causing severe injury or

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

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

resuming charging.

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

end of charging.

State of

Charge

Voltage

Action

Charge Time*

(Using constant current

charger @ standard amps

specified on top of battery)

100%

12.8-13.0 volts

12.5-12.8 volts

None, check at

3 mos. from date of

manufacture

None required

75%-100%

May need slight

charge, if no

charge given,

check in 3 months

3-6 hours

50%-75%

25%-50%

12.0-12.5 volts

11.5-12.0 volts

Needs Charge

5-11 hours

At least 13 hours,

verify state of charge

0%-25%

11.5 volts or less

Needs Charge

At least 20 hours

136

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MAINTENANCE AND LUBRICATION

Cleaning and Storage

See page 141 for the part numbers of Polaris-recommended products.

Cleaning the ATV

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

can also extend the life of various components. With a few

precautions, your ATV can be cleaned much like an automobile.

Washing the ATV

The best and safest way to clean your ATV is with a garden hose and a

pail of mild soap and water. Use a professional type washing mitten,

cleaning the upper body first and the lower parts last. Rinse with water

frequently and dry with a chamois to prevent water spots. NOTE: If

warning and safety labels are damaged, contact your a Polaris dealer

for free replacement.

Polaris does not recommend the use of a high pressure type car wash

system for washing the ATV. If a high pressure system is used,

exercise extreme care to avoid water damage to the wheel bearings,

transmission seals, body panels, brakes and warning labels. NOTE:

Grease all zerk fittings immediately after washing, and allow the

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

the engine or exhaust system.

Waxing the ATV

Your ATV can be waxed with any non-abrasive automotive paste wax.

Avoid the use of harsh cleaners since they can scratch the body finish.

CAUTION

Certain products, including insect repellants and chemicals, will

damage plastic surfaces. Use caution when using these products

near plastic surfaces.

137

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MAINTENANCE AND LUBRICATION

Cleaning and Storage

Storage Tips

See page 141 for the part numbers of Polaris-recommended products.

CAUTION

Starting the engine during the storage period will disturb the protective

film created by fogging and damage could occur. Never start the

engine during the storage period.

Clean the Exterior

Make necessary repairs and then clean the ATV thoroughly with mild

soap and warm water to remove all dirt and grime. Don’t use harsh

detergents or high pressure washers. Some detergents deteriorate rubber

parts. Use dish soap type cleaners only. High pressure washers may

force water past seals.

Stabilize the Fuel

Fill the fuel tank. Add Polaris Carbon Clean Fuel Treatment or Polaris

Fuel Stabilizer. Follow the instructions on the container for the

recommended amount. (Carbon clean will also reduce the possibility of

bacterial growth in the fuel system.) Allow 15-20 minutes of operation

for the stabilizer to disperse through the fuel in the tank and carburetor.

Turn the fuel valve off and drain the carburetor bowl.

Oil and Filter - 4-Cycle

Warm the engine and change the oil and filter.

Air Filter / Air Box

Inspect and clean or replace the pre-cleaner and air filter. Clean the air

box and drain the sediment tube.

Breather Filter(s)

On 4-cycle engines, inspect and clean or replace the breather filter(s).

Fluid Levels

Inspect the following fluid levels and change if necessary: engine

counter balance (2-cycle); front gearcase (shaft drive models);

transmission; front hubs (AWD models); brake fluid (change every two

years or as required if fluid looks dark or contaminated).

Drain the Recoil Housing

Remove the recoil housing drain plug and drain any moisture.

138

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MAINTENANCE AND LUBRICATION

Cleaning and Storage

Storage Tips

See page 141 for the part numbers of Polaris-recommended products.

Fog the Engine

2 Cycle - Use Polaris Fogging Oil and follow the directions on the can.

4-Cycle - Remove the spark plug and add 2-3 tablespoons of Premium 4

Synthetic 0W40 engine oil. To access the plug hole, use a section of clear

1/4” hose and a small plastic squeeze bottle filled with the pre-measured

amount of oil. Note: Do this carefully! If you miss the plug hole, oil will

drain from the spark plug cavity into the hole at the front of the cylinder

head, and appear to be an oil leak. Install the spark plug and pull the

engine over slowly with 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.

If you choose not to use Polaris Fogging Oil, perform the following

procedure.

1. Support the front end of the machine so the engine is level or tilted

slightly rearward.

2. Remove the spark plug(s). Rotate the piston to BDC and pour

approximately two ounces of Polaris-recommended oil into the

cylinder. NOTE: Be sure to use 2-cycle oil in 2-cycle engines and

4-cycle oil in 4-cycle engines.

3. Apply dielectric grease to the inside of the spark plug cap and install

the cap onto the plug.

4. Turn the engine over several times to ensure coverage of piston

rings, cylinder walls and crankshaft bearings.

5. Treat the fuel system with Polaris Carbon Clean.

6. If Polaris fuel system additive is not used, fuel tank, fuel lines, and

carburetor should be completely drained of gasoline. To eliminate

any fuel remaining in the carburetor, run the engine until it stops.

Lubricate

Inspect all cables and lubricate with Polaris Cable Lubricant. Follow

lubrication guidelines in the maintenance section of the service or

owner’s manual to completely grease and lubricate the entire vehicle

with Polaris Premium All Season Grease. Apply Polaris O-Ring Chain

Lube to the drive chain(s).

139

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MAINTENANCE AND LUBRICATION

Cleaning and Storage

Storage Tips

Battery Storage

Conventional Battery: Remove the battery and add distilled water to

the proper level. Do not use tap water, which may contain minerals

that reduce battery life. Apply Polaris di-electric grease to the terminal

bolts and terminals. Charge the battery at 1.4 amps or less until the

specific gravity of each cell is 1.265 or greater. While the battery is in

storage, check the fluid level once a month.

Sealed Battery: Remove the battery and ensure that it’s fully charged.

See page 135 for instructions.

Both battery types should be stored in a cool, dry place. Battery charge

can be maintained easily by using Polaris Battery Tendert charger

(PN 2871076) or by charging about once a month to make up for

normal self-discharge. Battery Tendert can be left connected during

the storage period, and will automatically charge the battery if the

voltage drops below a pre-determined point.

Engine Anti-Freeze

Test engine coolant strength and change if necessary. Coolant should

be replaced every two years.

Storage Area/Covers

Set the tire pressure and safely support the ATV with the tires 1-2” off

the ground. Be sure the storage area is well ventilated, and cover the

machine with a genuine Polaris ATV cover. NOTE: Do not use plastic

or coated materials. They do not allow enough ventilation to prevent

condensation, and may promote corrosion and oxidation.

Transporting the ATV

Follow these procedures when transporting the vehicle.

1. Turn off the engine and remove the key to prevent loss during

transporting.

2. Turn the fuel valve off.

3. Be sure the fuel cap, oil cap and seat are installed correctly.

4. Always tie the frame of the ATV to the transporting unit securely

using suitable straps or rope.

5. Always place the transmission in gear and lock the parking brake.

140

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POLARIS RECOMMENDED PRODUCTS

Part No.

Description

Engine Lubricant

2870791

2871098

2871721

2871281

Fogging Oil (12 oz. Aerosol)

Premium 2-Cycle Engine Oil (qt.)

Premium Gold Synthetic 2-Cycle Oil (qt.)

Premium 4 Synthetic 0W-40 Engine Oil (4-Cycle)(qt.)

Gearcase / Transmission Lubricants

Premium Synthetic Gearcase Lubricant (qt.)

Premium Front Gearcase Lube (8 oz.)

Premium Drive Hub Fluid (8 oz.)

2873602

2871653

2871654

Grease / Specialized Lubricants

Grease Gun Kit, Premium All Season (3 oz.)

Premium All Season Grease (3 oz. cartridge)

Premium All Season Grease (14 oz. cartridge)

Starter Drive Grease (2 oz.)

2871312

2871322

2871423

2871460

2871515

2871551

2871329

Premium U-Joint Lube (3 oz.)

Premium U-Joint Lube (14 oz.)

Dielectric Grease (Nyogelt)

Coolant

2871323

2871534

60/40 Coolant (gal.)

60/40 Coolant (qt.)

Additives / Miscellaneous

Carbon Clean Plus (12 oz.)

Fuel Stabilizer (16 oz.)

2871326

2870652

2870990

2872893

DOT3 Brake Fluid (12 oz.)

Engine Degreaser (12 oz.)

141

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TROUBLESHOOTING

Drive Belt and Cover Problems

Possible Cause

Solution

Driving the ATV onto a

pickup or tall trailer in

high range.

Shift transmission to low range during loading of the ATV

to prevent belt burning.

Starting out going up a

steep incline.

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

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

perform the K-turn as described on page 69.

Driving at low RPM or

low ground speed (at

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

The use of low range is highly recommended for cooler

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

Insufficient warm-up of Warm the engine at least 5 minutes. With the transmission

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

bient temperatures.

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

ible and prevent belt burning.

Slow and easy clutch en- Use the throttle quickly and effectively for efficient enga-

gagement.

gement.

Towing/pushing at low

RPM/low ground speed.

Use low range only.

Utility use/plowing snow, Use low range only.

dirt, etc.

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 ob-

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

jects from a stopped posi- brief, aggressive throttle application to engage clutch.

tion.

WARNING: Excessive throttle may cause loss of control

and vehicle overturn.

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

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

PVT system.

times as required. During this procedure, the throttle

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

seconds. Clutch seals should be inspected for damage if

repeated leaking occurs.

Clutch malfunction.

Contact your Polaris dealer for inspection of clutch com-

ponents.

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

fuel lines, or carburetor. Contact your dealer for service.

142

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TROUBLESHOOTING

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

solutions using the following charts.

Engine Doesn’t Turn Over

Possible Cause

Solution

Tripped circuit breaker

Low battery voltage

Reset the breaker

Recharge battery to 12.5 VDC

Check all connections and tighten

Loose battery connections

Loose solenoid connections

Engine Turns Over, Fails to Start

Possible Cause

Solution

Out of fuel

Turn fuel valve to reserve, refuel

Inspect and clean or replace

Drain the fuel system and refuel

Turn the fuel valve on

Clogged fuel valve or filter

Water is present in fuel

Fuel valve is turned off

Old or non-recommended fuel

Fouled or defective spark plug(s)

No spark to spark plug

Crankcase filled with water or fuel

Overuse of choke

Replace with new fuel

Inspect plug(s), replace if necessary

Inspect plug(s), verify stop switch is on

Immediately see your Polaris dealer

Inspect, clean and/or replace spark plugs

Replace the filter

Clogged fuel filter

Low battery voltage

Recharge battery to 12.5 VDC

See your Polaris dealer

Mechanical failure

Engine Pings or Knocks

Possible Cause

Solution

Poor quality or low octane fuel

Incorrect ignition timing

Replace with recommended fuel

See your Polaris dealer

Set gap to specs or replace plugs

Incorrect spark plug gap or heat range

143

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TROUBLESHOOTING

Engine Backfires

Possible Cause

Solution

Weak spark from spark plugs

Incorrect spark plug gap or heat range

Old or non-recommended fuel

Incorrectly installed spark plug wires

Incorrect ignition timing

Inspect, clean and/or replace spark plugs

Set gap to specs or replace plugs

Replace with new fuel

See your Polaris dealer

Mechanical failure

Engine Runs Irregularly, Stalls or Misfires

Possible Weak Spark Cause

Fouled or defective spark plugs

Worn or defective spark plug wires

Incorrect spark plug gap or heat range

Loose ignition connections

Water present in fuel

Solution

Inspect, clean and/or replace spark plugs

See your Polaris dealer

Set gap to specs or replace plugs

Check all connections and tighten

Replace with new fuel

Low battery voltage

Recharge battery to 12.5 VDC

Inspect and replace

Kinked or plugged fuel vent line

Incorrect fuel

Replace with recommended fuel

Inspect and clean or replace

See your Polaris dealer

Clogged air filter

Reverse speed limiter malfunction

Electronic throttle control malfunction

Other mechanical failure

See your Polaris dealer

Possible Lean Fuel Mixture Cause Solution

Low or contaminated fuel

Low octane fuel

Add or change fuel, clean the fuel system

Replace with recommended fuel

Replace filter

Clogged fuel filter

Incorrect jetting

See your Polaris dealer

Possible Rich Fuel Mixture Cause Solution

Overuse of choke

Fuel is very high octane

Incorrect jetting

Inspect, clean and/or replace spark plugs

Replace with lower octane fuel

See your Polaris dealer

144

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TROUBLESHOOTING

Engine Stops or Loses Power

Possible Cause

Solution

Out of fuel

Turn fuel valve to reserve, refuel

Inspect and replace

Kinked or plugged fuel vent line

Water present in fuel

Replace with new fuel

Overuse of choke

Inspect, clean and/or replace spark plugs

See your Polaris dealer

Fouled or defective spark plugs

Worn or defective spark plug wires

Incorrect spark plug gap or heat range

Loose ignition connections

Low battery voltage

Set gap to specs or replace plugs

Check all connections and tighten

Recharge battery to 12.5 VDC

Replace with recommended fuel

Inspect and clean or replace

See your Polaris dealer

Incorrect fuel

Clogged air filter

Reverse speed limiter malfunction

Electronic throttle control malfunction

Other mechanical failure

Overheated engine

See your Polaris dealer

Clean radiator screen and core if equipped

Clean engine exterior

See your Polaris dealer

145

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WARRANTY

LIMITED WARRANTY

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

SIX MONTH LIMITED WARRANTY on all components of the

Polaris All Terrain Vehicle (ATV) against defects in material or

workmanship. Polaris also gives a one year limited warranty on the

final drive chain for failure due to defects. This warranty covers the

parts and labor charges for repair or replacement of defective parts

which are covered by this warranty. This warranty begins on the date

of purchase. This warranty is transferrable to another consumer during

the warranty period through a Polaris dealer.

REGISTRATION

At the time of sale, the Warranty Registration Form must be completed

by your dealer and submitted to Polaris within ten days. Upon receipt

of this registration, Polaris will record the registration for warranty.

THE PURCHASER MUST COMPLETE AN ATV SAFETY

TRAINING COURSE PROVIDED BY THE DEALER IN ORDER

TO HAVE VALID WARRANTY ON THE ATV. No verification of

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

Registration Form will be the warranty entitlement. If you have not

signed the original registration and received the “customer copy”,

please contact your dealer immediately. NO WARRANTY

COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS

REGISTERED WITH POLARIS.

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

ensuring trouble-free operation. Purchasing a machine in the crate or

without proper dealer set-up will void your warranty coverage.

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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

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

or for any damages which occur during trailer transit or as a result of

unauthorized service or the use of unauthorized parts. In 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.

This warranty does not cover the use of unauthorized lubricants,

chemicals, or fuels that are not compatible with the ATV. The exclusive

remedy for breach of this warranty shall be, at Polaris’ exclusive

option, repair or replacement of any defective materials, or components

or products. THE REMEDIES SET FORTH IN THIS WARRANTY

ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR

BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO

LIABILITY TO ANY PERSON FOR INCIDENTAL,

CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY

DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR

IMPLIED WARRANTY OR ANY OTHER 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.

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WARRANTY

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED

TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND

FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN

DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD.

POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES

NOT STATED IN THIS WARRANTY. Some states do not allow

limitations on how long an implied warranty lasts, so the above

limitation may not apply to you if inconsistent with controlling state

law.

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 personnel at Polaris.

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

other rights which vary from state to state.

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

other warranty terms will remain in effect.

Engine Oil

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

damage. We recommend the use of Polaris engine oil.

2. Damage resulting from the use of non-recommended lubricants may

not be covered by warranty.

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INDEX

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . 102-117

FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . 48-55

Filter Systems . . . . . . . . . . . . . . . . . . . . . . . 118-119

Front Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Front Gearcase Oil Change . . . . . . . . . . . . . . . . . 95

Front Gearcase Oil Check . . . . . . . . . . . . . . . . . . 95

Front Wheel Hub Tightening . . . . . . . . . . . . . . 114

Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Fuel Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Fuel Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Fuel Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

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

Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 118-119

All Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . 48-49

Auxiliary Brake . . . . . . . . . . . . . . . . . . . . . 42, 105

AWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48-49

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . 134-136

Battery (Conventional) . . . . . . . . . . . . . . . . . . . 133

Battery Charging (Sealed Battery) . . . . . . 135-136

Battery Fluid (Conventional) . . . . . . . . . . . . . . 134

Battery Installation . . . . . . . . . . . . . . . . . . . . . . 135

Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . 134

Battery Storage . . . . . . . . . . . . . . . . . . . . . 135, 140

Belt Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Break in Period (2-Cycle) . . . . . . . . . . . . . . . . . . 56

Break in Period (4-Cycle) . . . . . . . . . . . . . . . . . . 57

Break-In Period . . . . . . . . . . . . . . . . . . . . . . 56-57

Breather Filter/Hose . . . . . . . . . . . . . . . . . . . . . 119

Gear Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Gearcase Oil Fill Chart . . . . . . . . . . . . . . . . . . . . 91

Handlebars . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Hauling Cargo . . . . . . . . . . . . . . . . . . . . . . . . 61-62

Headlight Adjustment - Trail Blazer . . . . . . . . . 121

Headlight Housing Replacement - Gen IV . . . . 124

Headlight Lamp Replacement - Gen IV . . . . . . 122

Headlight Lamp Replacement - Scrambler . . . . 120

Headlight Lamp Replacement - Trail Blazer . . . 121

Helmet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

High Beam Adjustment - Gen IV . . . . . . . . . . . 123

High Beam Adjustment - Scrambler . . . . . . . . . 120

High Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Camber and Caster . . . . . . . . . . . . . . . . . . . . . . 107

Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . 109-110

Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Cleaning and Storage . . . . . . . . . . . . . . . . 137-140

Cleaning the ATV . . . . . . . . . . . . . . . . . . . . . . . 137

Cold Weather Operation (4-Cycle) . . . . . . . . . . . 60

CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . 37-47

Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Counter Balance Oil Check - 400 Engines . . . . . 97

Counterbalance Oil Change - 400 Engines . . . . . 97

Cylinder Head/Cylinder Base Fastener . . . . . . . 115

Indicator Lamp Replacement . . . . . . . . . . . . . . 125

Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . 50

Instrument Cluster . . . . . . . . . . . . . . . . . . . . 51-55

K-turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Diagnostic Mode . . . . . . . . . . . . . . . . . . . . . . . . . 55

Disengaging Wheel Hubs . . . . . . . . . . . . . . . . . . 49

Drive Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Driving Downhill . . . . . . . . . . . . . . . . . . . . . . . . 68

Driving in Reverse . . . . . . . . . . . . . . . . . . . . . . . 72

Driving on Slippery Surfaces . . . . . . . . . . . . . . . 65

Driving Over Obstacles . . . . . . . . . . . . . . . . . . . . 71

Driving Procedures . . . . . . . . . . . . . . . . . . . . . . . 63

Driving Safely . . . . . . . . . . . . . . . . . . . . . . . 63-73

Driving Through Water . . . . . . . . . . . . . . . . . . . . 70

Driving Uphill . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Light Switches . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120-125

Low Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Lubrication Recommendations . . . . . . . . . . . 80-98

Main Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

MAINTENANCE AND LUBRICATION . 75-140

Maintenance Record . . . . . . . . . . . . . . . . . . . . . . 84

Making Turns . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Electrical Switches . . . . . . . . . . . . . . . . . . . . . . . 37

Engaging Wheel Hubs . . . . . . . . . . . . . . . . . . . . 48

Engine Cooling System . . . . . . . . . . . . . . . 99-101

Engine Fogging . . . . . . . . . . . . . . . . . . . . . . . . 139

Engine Oil Check . . . . . . . . . . . . . . . . . . . . . . . . 98

Equipment Modifications . . . . . . . . . . . . . . . . . . 11

NOISE CONTROL SYSTEM . . . . . . . . . . . . . 74

Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . 86-90

Oil Filter Change . . . . . . . . . . . . . . . . . . . . . 86-90

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INDEX

Oil Injection Tank . . . . . . . . . . . . . . . . . . . . . . . . 45

Oil Pump Adjustment - 250 Engines . . . . . . . . . 102

Oil Pump Adjustment - 400 Engines . . . . . . . . . 103

Oil Pump Bleeding - 2-Cycle Engines . . . . . . . 101

OPERATION . . . . . . . . . . . . . . . . . . . . . . . 56-73

Operator Safety . . . . . . . . . . . . . . . . . . . . . . . . 7-31

Override Switch . . . . . . . . . . . . . . . . . . . . . . . . . 37

Starting a Warm Engine . . . . . . . . . . . . . . . . . . . 60

Starting the Engine . . . . . . . . . . . . . . . . . . . . 59-60

Steering Assembly . . . . . . . . . . . . . . . . . . . . . . 107

Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Storage Tips . . . . . . . . . . . . . . . . . . . . . . . 138-140

TABLE OF CONTENTS . . . . . . . . . . . . . . . . . .

Taillight/Brakelight Lamp Replacement . . . . . . 125

Throttle Cable Freeplay . . . . . . . . . . . . . . . . . . 110

Throttle Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Tire Tread Depth . . . . . . . . . . . . . . . . . . . . . . . . 114

Toe Alignment . . . . . . . . . . . . . . . . . . . . . . . . . 106

Towing Capacities . . . . . . . . . . . . . . . . . . . . . . . . 61

Transmission Gear Selector . . . . . . . . . . . . . . . . 46

Transmission Oil Change - 2x4 Models . . . . 93-94

Transmission Oil Change - Models w/Fill Plug . . 92

Transmission Oil Change - Sportsman . . . . . . . . 94

Transmission Oil Check - Models w/Dipstick . . . 93

Transmission Oil Check - Models w/Fill Plug . . . 91

Transporting the ATV . . . . . . . . . . . . . . . . . . . . 140

Trip Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

TROUBLESHOOTING . . . . . . . . . . . . . 142-145

Turning Around on a Hill . . . . . . . . . . . . . . . . . . 69

Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Parking on an Incline . . . . . . . . . . . . . . . . . . . . . 73

Periodic Maintenance Schedule . . . . . . . . . . 75-79

POLARIS RECOMMENDED PRODUCTS . 141

Pre Ride Inspection . . . . . . . . . . . . . . . . . . . . . . . 58

Premium 2-Cycle Oil . . . . . . . . . . . . . . . . . . . . . 85

Premium 4 Synthetic Oil . . . . . . . . . . . . . . . . . . . 86

Premium Gold Synthetic 2-Cycle Oil . . . . . . . . . 85

Programmable Service Interval . . . . . . . . . . . . . . 54

PVT Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

PVT System . . . . . . . . . . . . . . . . . . . . . . . 131-132

Radiator Coolant Level . . . . . . . . . . . . . . . . . . 100

Rear Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Rear Drive Chain Slack . . . . . . . . . . . . . . . . 116-117

Rear Gearcase Oil Change . . . . . . . . . . . . . . . . . 96

Rear Gearcase Oil Check . . . . . . . . . . . . . . . . . . 96

Rear Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Recoil Housing . . . . . . . . . . . . . . . . . . . . . . . . . 130

Recoil Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Rider Information Center . . . . . . . . . . . . . . . 52-55

USFS Approved Spark Arrestor . . . . . . . . . . . . . 74

VEHICLE IDENTIFICATION NUMBERS . . .

Vehicle Immersion . . . . . . . . . . . . . . . . . . . . . . 127

Safe Riding Gear . . . . . . . . . . . . . . . . . . . . . . . . . 36

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36

Safety Decals and Locations . . . . . . . . . . . . . 32-35

Warning, Read Your Owner’s Manual . . . . . . . . .

WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . 146-147

Washing the ATV . . . . . . . . . . . . . . . . . . . . . . . 137

Waxing the ATV . . . . . . . . . . . . . . . . . . . . . . . . 137

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

Side Panel Removal - Gen IV . . . . . . . . . . . . . . 111

Sidehilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Spark Arrestor . . . . . . . . . . . . . . . . . . . 74, 128-129

Spark Plug Removal and Replacement . . . . . . . 126

Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Starting a Cold Engine . . . . . . . . . . . . . . . . . . . . 59

WELCOME . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . 113

Wheel Nut Torque Specifications . . . . . . . . . . . 113

Wheel Removal . . . . . . . . . . . . . . . . . . . . . . . . 112

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WARNING

Improper vehicle use can result in SEVERE INJURY or DEATH.

NEVER CARRY

PASSENGERS

NEVER USE

ON PUBLIC

ROADS

NEVER USE

WITH DRUGS

OR ALCOHOL

ALWAYS USE

AN APPROVED

HELMET AND

PROTECTIVE

GEAR

NEVER:

Operate without proper training or instruction.

Operate on public roads. A collision can occur with another vehicle.

Operate at speeds too fast for your skills or the conditions.

Use ALCOHOL or DRUGS before or while operating this vehicle.

Carry Passengers.

ALWAYS:

Avoid paved surfaces, which may adversely affect handling and control.

Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills

and rough terrain, and in turns.

Wear eye protection, helmet and protective apparel.

READ OWNER'S MANUAL.

FOLLOW ALL INSTRUCTIONS AND WARNINGS.

Part No. 9917492 Rev. 05

PRINTED IN THE USA

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