Polaris Offroad Vehicle Sprotsman MV7 User Manual

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WARNING

The engine exhaust from this

product contains chemicals known

to cause cancer, birth defects or

other reproductive harm.

A card containing important ATV safety information should be attached

to the owner’s manual on the next page. If you cannot locate this card,

or if it has been removed, please call 1-800-342-3764 for assistance.

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

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

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

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

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

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

expressly prohibited.

Printed in U.S.A.

2005 Sportsman MV7 Owner’s Manual P/N 9919959

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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 Watercraft

S RANGER utility vehicles

S Victory motorcycles

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

recreational vehicles manufactured in the world today. Many years of

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

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

produced.

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

instructions and recommendations in this owner’s manual. Your

manual contains instructions for minor maintenance, but information

about major repairs is outlined in the Polaris Service Manual and

should be performed only by a Factory Certified Master Service Dealer

(MSD) Technician.

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

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

service needs during, and after, the warranty period.

We also take great pride in our 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 and POLARIS THE WAY OUT are registered trademarks of

Polaris Industries Inc.

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TABLE OF CONTENTS

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

VEHICLE IDENTIFICATION NUMBERS . . . . . . . . . . . 7

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . 68

MAINTENANCE AND LUBRICATION . . . . . . . . . . . . 69

ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

POLARIS PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . 114

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 115

WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

MAINTENANCE RECORD . . . . . . . . . . . . . . . . . . . . 124

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

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VEHICLE IDENTIFICATION NUMBERS

Record your vehicle’s identification numbers and key number in the

spaces provided. Remove the spare key and store it in a safe place.

Your key can be duplicated only by mating a Polaris key blank with

one of your existing keys, so if both keys are lost, the ignition switch

must be replaced.

31XX

Vehicle Model Number:

Frame VIN (1):

Engine Serial Number (2):

Key Number (3):

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SAFETY

Safety Decals and Locations

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

Read and follow the instructions of the decals carefully. If any of the

decals depicted in this manual differ from the decals on your vehicle,

always read and follow the instructions of the decals on the vehicle.

If any decal becomes illegible or comes off, contact your Polaris dealer

to purchase a replacement. Replacement safety decals are provided by

Polaris at no charge. The part number is printed on the decal.

WARNING

Improper ATV use can result in SEVERE INJURY or DEATH

ALWAYS USE

AN APPROVED

HELMET AND

PROTECTIVE

GEAR

NEVER USE

ON PUBLIC

ROADS

NEVER CARRY

PASSENGERS

NEVER USE

WITH DRUGS

OR ALCOHOL

NEVER operate:

ALWAYS:

7172560

WARNING

7172561

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SAFETY

Safety Decals and Locations

WARNING

IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of

control resulting in SEVERE INJURY OR DEATH.

TIRE PRESSURE IN PSI (KPa): FRONT 5 (34.5) REAR 5 (34.5)

MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight)

INCLUDING MACHINE, DRIVER AND CARGO IS 1700 LBS. (771 kg).

This vehicle is equipped with run-flat tires. In the event of a flat tire, remove all

cargo from the vehicle before riding further. Do not exceed 50 miles (80 km) at

25 MPH (40 km/h). Have the tire inspected by a dealer before further use.

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

7173016

WARNING

7172566

ATTENTION

Specific carburetor jetting and

Operation of this vehicle without the air

filter element will severely damage the

engine.

Clean pre-filter element often, more

frequent cleaning required in dusty

conditions. Do not operate vehicle

without pre-filter.

adjustments are required depending

on temperature and altitude. See

your Owner’s Manual.

Factory setting:

40_ to 80_ F. at 0-3000 feet

(5_ to 27_ C. at 0-900 meters).

7172922

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SAFETY

Safety Decals and Locations

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.

Operating this ATV if you are under

the age of 16 increases your chance

of severe injury or death.

NEVER operate this ATV if you are

under age 16.

NO STEP

7172563

7172559

WARNING

DO NOT TOW FROM RACK OR BUMPER.

Vehicle damage or tipover may result causing severe injury

or death. Tow only from tow hooks or hitch.

Max Rack Loads: Front 150 lbs. (68 kg) Rear 300 lbs. (136 kg)

7172927

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SAFETY

Safety Decals and Locations

WARNING

ALL WHEEL

Pushing reverse

override button

may cause

DRIVE

SWITCH

sudden increases

in power and

Do not push switch to

engage AWD if the rear

wheels are spinning.

This may cause severe

drive shaft and clutch

damage.

traction if too

much throttle is

applied. Loss of

control or forward

flipover may

result, especially

in AWD. See

Owner’s Manual.

See your Owner’s

Manual.

7172564

7079780

MANUFACTURED

BY: POLARIS IND. INC.

DATE:

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.

7171492

Canadian Certification Decal

TRAILER MAX WEIGHT:

1500 LBS. (682 KG) ON LEVEL GROUND

850 LBS. (386 KG) UP TO 15° GRADE

HITCH MAX. VERTICAL WEIGHT: 150 LBS. (68KG)

7170509

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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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SAFETY

Operator Safety

WARNING

Failure to follow the warnings contained in this manual can result

in serious injury or death.

A Polaris ATV is not a toy and can be hazardous to operate. This

vehicle handles differently than other vehicles, such as

motorcycles and cars. A collision or rollover can occur quickly,

even during routine maneuvers like turning, or driving on hills or

over obstacles, if you fail to take proper precautions.

Read and understand your owner’s manual and all warnings

before operating a Polaris ATV.

Age Restrictions

This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited

for anyone under 16 years of age.

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 the ATV in your area.

We strongly advise you to strictly follow the recommended

maintenance program outlined in your owner’s manual. This

preventive maintenance program is designed to ensure that all critical

components on your vehicle are thoroughly inspected at specific

intervals.

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SAFETY

Operator Safety

The following two pages identify signal words and symbols that appear

in this manual. Your safety is involved when these words and symbols

are used. Become familiar with their meanings before reading the

manual.

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

you to the potential for personal injury.

WARNING

The safety alert warning indicates a potential hazard that may

result in serious injury or death.

CAUTION

The safety alert caution indicates a potential hazard that may

result in minor personal injury or damage to the vehicle.

CAUTION

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

vehicle.

NOTE:

A note will alert you to important information or instructions.

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SAFETY

Operator Safety

WARNING

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

instructions and procedures, which are outlined in further detail

within your owner’s manual.

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

procedures described.

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

course. 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 ascending a hill. Never climb hills with exces-

sively 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

procedure 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

described 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 the 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.

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.

WARNING

POTENTIAL HAZARD

Operating an ATV

on paved

surfaces, including

sidewalks, paths,

parking lots, and

driveways.

WHAT CAN HAPPEN

ATV tires are designed for

off-road use. Operating on

paved surfaces may

seriously affect the handling and

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

and/or injury.

HOW TO AVOID THE HAZARD

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

slowly and avoid sudden turns or stops.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating this ATV on

public streets, roads or

highways.

WHAT CAN HAPPEN

The ATV could collide

with another vehicle.

HOW TO AVOID THE HAZARD

Never operate the ATV on any

public street, road or highway,

including dirt and gravel roads. In many states

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

WARNING

POTENTIAL HAZARD

Operating this ATV without

wearing an approved

helmet, eye protection and

protective clothing.

WHAT CAN HAPPEN

Operating an ATV without

an approved helmet

increases the risk of a

severe head injury or

death in the event of an

accident.

Operating without eye protection could result in an accident and

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

accident.

HOW TO AVOID THE HAZARD

Always wear an approved helmet that fits properly.

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

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

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating the ATV after consuming

alcohol or drugs.

WHAT CAN HAPPEN

Consumption of alcohol and/or drugs

could seriously affect operator

judgment. Reaction time may be slower

and operator balance and perception

could be affected.

Consuming alcohol and/or drugs before

or while operating an ATV could result in

an accident causing severe injury or death.

HOW TO AVOID THE HAZARD

Never consume alcohol or drugs before or while operating an

ATV.

WARNING

POTENTIAL HAZARD

Operating the ATV at excessive speeds.

WHAT CAN HAPPEN

Excessive speed increases the operator’s chance of losing

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

HOW TO AVOID THE HAZARD

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

visibility and operating conditions, and your experience.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Attempting wheelies, jumps

and other stunts.

WHAT CAN HAPPEN

Attempting stunts increases

the chance of an accident,

including an overturn.

HOW TO AVOID THE

HAZARD

Never attempt wheelies,

jumps, or other stunts. Avoid

exhibition driving.

WARNING

POTENTIAL HAZARD

Failure to inspect the ATV before operating.

Failure to properly maintain the ATV.

WHAT CAN HAPPEN

Poor maintenance increases the possibility of an accident or

equipment damage.

HOW TO AVOID THE HAZARD

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

safe operating condition.

Always follow the inspection and maintenance procedures and

schedules described in the owner’s manual.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Removing hands from the handlebars or feet from the footrests

during operation.

WHAT CAN HAPPEN

Removing even one hand or foot can reduce ability to control the

vehicle or could cause loss of balance and ejection from the ATV.

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

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

injury.

HOW TO AVOID THE HAZARD

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

footrests of the ATV during operation.

WARNING

POTENTIAL HAZARD

Failure to use extra

caution when operating

the ATV on unfamiliar

terrain.

WHAT CAN HAPPEN

Unfamiliar terrain may

contain hidden rocks,

bumps, or holes that could

cause loss of control or

overturn.

HOW TO AVOID THE HAZARD

Travel slowly and use extra caution when operating on unfamiliar

terrain. Always be alert to changing terrain conditions.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Failure to use extra

caution when operating on

excessively rough,

slippery or loose terrain.

WHAT CAN HAPPEN

Operating on excessively

rough, slippery or loose

terrain could cause loss of

traction or loss of control,

which could result in an

accident or overturn.

HOW TO AVOID THE HAZARD

Do not operate on excessively rough, slippery or loose terrain

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

the ATV on such terrain.

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

WARNING

POTENTIAL HAZARD

Turning improperly.

WHAT CAN HAPPEN

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

or overturn.

HOW TO AVOID THE HAZARD

Always follow proper procedures for turning as described in the

owner’s manual.

Practice turning at slow speeds before attempting to turn at faster

speeds.

Never turn at excessive speed.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating on excessively steep hills.

WHAT CAN HAPPEN

The vehicle may overturn.

HOW TO AVOID THE HAZARD

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

Never operate the ATV on hills steeper than 25_.

Practice on smaller hills before attempting large hills.

WARNING

POTENTIAL HAZARD

Climbing hills improperly.

WHAT CAN HAPPEN

Improper hill climbing could

cause loss of control or

overturn.

HOW TO AVOID THE

HAZARD

Always follow proper

procedures for climbing

hills as described in the

owner’s manual.

Always check the terrain

carefully before ascending

any hill.

Never operate the ATV on hills steeper than 25_.

Never climb hills with excessively slippery or loose surfaces.

Shift your weight forward.

Never open the throttle suddenly while traveling uphill. The ATV

could flip over backwards.

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

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

side of the hill.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Traveling downhill

improperly.

WHAT CAN HAPPEN

Improperly descending a hill

could cause loss of control

or overturn.

HOW TO AVOID THE

HAZARD

Always follow proper

procedures for traveling

down hills as described in

the owner’s manual. NOTE:

A special technique is

required when braking while

traveling downhill. See page 61.

Always check the terrain carefully before descending a hill.

Shift your weight backward.

Never travel down a hill at high speed.

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

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

when possible.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Improperly crossing hills and

turning on hills.

WHAT CAN HAPPEN

Improperly crossing or

turning as hills could cause

loss of control or overturn.

HOW TO AVOID THE

HAZARD

Never attempt to turn the

ATV around on any hill until

you’ve mastered the turning

technique (on level ground)

as described in the owner’s

manual. See page 62. 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 brakes.

Lock the parking brake when fully stopped.

If the ATV begins rolling backwards:

Keep weight uphill.

Never apply engine power.

Never apply the rear brake while rolling backwards.

Apply the single-lever brake gradually.

When fully stopped, apply the rear brake as well, and then lock

the parking brake.

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

uphill.

Turn the ATV around and remount, following the procedure

described in the owner’s manual. See page 62.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Improperly operating over obstacles.

WHAT CAN HAPPEN

Operating over obstacles could cause loss of control or overturn.

HOW TO AVOID THE HAZARD

Before operating in a new area, check for obstacles.

Avoid operating over large obstacles such as rocks and fallen

trees when possible. If unavoidable, use extreme caution and

always follow proper procedures as outlined in the owner’s

manual.

WARNING

POTENTIAL HAZARD

Skidding or sliding.

WHAT CAN HAPPEN

Skidding or sliding can cause loss of control.

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

HOW TO AVOID THE HAZARD

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

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

WARNING

POTENTIAL HAZARD

Improperly operating in reverse.

WHAT CAN HAPPEN

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

severe injury.

HOW TO AVOID THE HAZARD

Before shifting into reverse gear, always check for obstacles or

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

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating the ATV through deep or fast-flowing water.

WHAT CAN HAPPEN

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

could lead to an accident or overturn.

HOW TO AVOID THE HAZARD

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

unavoidable to enter water that exceeds the recommended

maximum depth (see page 64), travel slowly, balance your weight

carefully, avoid sudden movements, and maintain a slow and

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

do not make sudden throttle changes.

Wet brakes may have reduced stopping ability. Always test the

brakes after leaving water. If necessary, apply them several

times to let friction dry out the pads.

WARNING

POTENTIAL HAZARD

Operating this ATV with improper tires, or with improper or

uneven tire pressure.

WHAT CAN HAPPEN

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

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

HOW TO AVOID THE HAZARD

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

Always maintain proper tire pressure as specified.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating the ATV with improper modifications.

WHAT CAN HAPPEN

Improper installation of accessories or modification of the ATV

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

HOW TO AVOID THE HAZARD

Never modify the ATV through improper installation or use of

accessories. All parts and accessories added to the vehicle must

be genuine Polaris Industries Inc. or equivalent components

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

according to approved instructions. See your authorized Polaris

ATV dealer for more information.

WARNING

POTENTIAL HAZARD

Overloading the ATV or carrying/towing cargo improperly.

WHAT CAN HAPPEN

Overloading and towing can cause changes in vehicle handling,

which could lead to loss of control or an accident.

HOW TO AVOID THE HAZARD

Never exceed the stated load capacity for this ATV.

Cargo should be properly distributed and securely attached.

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

greater distance for braking.

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

cargo or pulling a trailer. See page 54.

WARNING

POTENTIAL HAZARD

Operating on frozen bodies of water.

WHAT CAN HAPPEN

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

fall through the ice.

HOW TO AVOID THE HAZARD

Never operate the ATV on a frozen body of water.

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SAFETY

Operator Safety

WARNING

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

the vehicle resulting in serious injury or death. Always remove

the ignition key when the vehicle is not in use.

WARNING

After any overturn or accident, have a qualified service dealer

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

limited to) brakes, throttle and steering systems.

WARNING

Safe operation of this rider-active vehicle requires good

judgement and physical skills. Persons with cognitive or physical

disabilities who operate this vehicle have an increased risk of

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

death.

CAUTION

Exhaust system components are very hot during and after use of

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

Do not touch hot exhaust system components. Always keep

combustible materials away from the exhaust system. Use

caution when traveling through tall grass, especially dry grass.

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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.

Mode/Reverse Override Switch (1) - This 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 AWD in reverse,

if the AWD switch is on. This switch is also used to toggle

through the different modes of the rider information center.

See page 44.

Engine Stop Switch (2) - The engine will

OFF

RUN

not start or run when the switch is in the

OFF position. Its purpose is to provide the

operator with a quick means of engine

shutdown in case of an emergency.

Main Switch (3) - 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: Both the main switch and the emergency engine stop switch

will shut off all electrical power to the vehicle, including lights.

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

the OFF position.

Front/Rear Winch Switch (4) - Use the switch on the pod to select

either the front or rear winch.

Winch Operation Switch (5) - After selecting either the front or rear

winch with the switch on the pod, use the handlebar switch to operate

the winch. Winch operation instructions can be found in The Basic

Guide to Winching Techniques, provided by the winch manufacturer.

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CONTROLS

WARNING

Operating an ATV with sticking or improperly operating throttle

controls could cause an accident and lead to severe injury or

death.

Never start or operate an ATV with a sticking or improperly

operating throttle. Always contact your dealer for service 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 (1).

The throttle lever is spring

loaded. Engine speed returns

to idle when the lever is

released.

This ATV is equipped with Polaris Electronic Throttle Control (ETC),

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

throttle cable should stick in an open position when the operator

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

wheels will cease.

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

Light Switches

The light switch is located on the left handlebar. It’s used to turn the

lights on and off and to switch the lights from HI to LO.

NOTE: The lights won’t work unless the key is in the ON position

and the shut-off switch is in the RUN position.

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.

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

Master Cylinder

The brake fluid in the master

cylinder (1), which is located on the

left handlebar, should be checked

before each ride. The fluid level

can be seen through an indicator

window (2) on the top of the master

cylinder. This eye will appear dark

when the fluid level is full. When

fluid needs to be added, the eye will be clear.

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 114 for the part

numbers of Polaris 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

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.

Locking the Parking Brake

1. Place the transmission in PARK.

2. Squeeze and release the brake

lever (1) two or three times, then

squeeze and hold.

3. Push the park brake lock (2)

forward to engage the brake.

Release the brake lever.

4. 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 auxiliary 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.

Your Polaris ATV has an

auxiliary brake (1) for added

safety. It’s 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.

Brake Fluid Level

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

The reservoir is located under the seat or near the auxiliary 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 52 for correct choke and throttle settings during

starting.

Fuel Requirements

Use either leaded or unleaded gasoline with a minimum pump octane

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

Fuel Valve

REAR

TANK

The fuel valve (1) is located on the

left side panel.

OFF: Turn the fuel valve off for

vehicle storage and when transporting.

OFF

REAR TANK: We recommend using

the rear tank fuel supply first. Switch

FRONT

TANK

to the front tank when the rear tank is

empty. It will be easier to monitor

remaining fuel at the front tank gauge.

FRONT TANK: Use the front

tank fuel supply when the rear

tank is empty.

NOTE: There is no reserve fuel

supply on this vehicle. When

both fuel tanks are empty, the

vehicle will not operate.

Fuel Tanks

The front fuel tank filler cap (2) is

located directly below the

handlebar. The rear fuel tank and

filler cap (3) are located behind

the seat, under the rear rack.

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

Automatic Transmission Gear Selector

The transmission gear

selector (1) is located on

the right side of the

vehicle.

H: High Gear

L: Low Gear

N: Neutral

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

PARK and lock the parking brake.

Belt Life

To extend belt life, use low forward gear in heavy pulling situations and

when operating at less than seven miles per hour for extended periods of

time.

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FEATURES

Recoil Starter

If the battery has been drained or

damaged and cannot start the

engine, use of the recoil starter (1)

will allow vehicle operation until

repairs can be made. The recoil

starter is located on the right side of

the machine.

Polaris 4-cycle engines are

equipped with automatic

decompressors. This makes recoil

starting possible by reducing the

amount of compression during starting.

The decompressor senses when the engine is spinning

fast enough to start and restores compression when running.

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

(see page 37).

2. Shift the transmission into neutral.

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

switch is in the ON position.

NOTE: If the engine is cold, use the choke as outlined on page 52.

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

you can feel the engine strokes.

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

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

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

the stroke, then stop pulling immediately.

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

the rope abruptly and forcefully to start the engine.

6. Repeat steps 4-5 if necessary.

CAUTION

Extending the recoil starter rope until it stops can cause damage

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

it stops.

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

the recoil housing and damage components. Make sure the

handle is fully seated on the recoil housing, especially when

traveling in wet areas.

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FEATURES

Run-Flat Tires

This ATV is equipped with run-flat tires, which permit limited

operation with a flat tire. However, ATV load capacity is reduced when

tire air pressure is lost. Remove cargo from the racks and do not tow a

load with flat tires. Vehicle characteristics, including braking and

handling, may also be affected by operating with flat tires. If you must

operate the vehicle with a flat tire, drive no further and no faster than

necessary, and travel on smooth and level terrain whenever possible.

WARNING

Failure to reduce travel distance, vehicle speed and cargo weight

when air pressure is lost in run-flat tires could result in loss of

control or tire damage. This could lead to serious injury or death.

If you must operate the vehicle with flat tires, remove all cargo

and towed loads from the ATV, and do not exceed 50 miles (80

km) at 25 MPH (40 km/h).

Have the tire(s) inspected by an authorized Polaris dealer as

soon as possible and before further use.

Winches

Your vehicle is equipped with

both a front (1) and a rear (2)

winch. These winches operate

independently. Use the pod

switch to select one of the

winches. Use the handlebar

switch to operate the selected

winch.

Refer to the winch

manufacturer’s Basic Guide to

Winching Techniques,

provided with your ATV, for

complete winch operation

instructions.

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FEATURES

All Wheel Drive (AWD) System

Polaris 4-wheel drive ATVs are

equipped with a unique,

Polaris-exclusive, All Wheel Drive

(AWD) system, which is 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 AWD and the AWD

indicator light in the instrument

cluster will be on.

When in AWD, the front gearcase will automatically engage any time

the rear wheels lose traction. When the rear wheels regain traction, the

front gearcase will automatically disengage.

NOTE: The override switch allows activation of AWD in reverse if the

AWD switch is on. See page 33.

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

Engaging Front Gearcase

The AWD switch may be turned on or off while the vehicle is moving.

Initially, the vehicle’s electronic system will not enable the AWD until

the engine RPM is below 3100. Once enabled, the AWD remains

enabled until the AWD switch is turned off. If the switch is turned off

while the front gearcase is moving, it will not disengage until the rear

wheels regain traction.

Engage the AWD switch before getting into conditions where front

wheel drive may be needed. If the rear wheels are spinning, release the

throttle before switching to AWD.

CAUTION

Switching to AWD while the rear wheels are spinning may cause

severe drive shaft and gearcase damage. Always switch to AWD

while the rear wheels have traction or are at rest.

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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 or kilometers 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 33 for additional information.

1. Rider Information Center

2. Speedometer needle - in addition to showing vehicle speed, the

needle flashes when a warning condition exists.

3. Speedometer

CAUTION

To prevent damage, wash the vehicle 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. Do not allow insect sprays to come into

contact with the lens.

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FEATURES

Instrument Cluster

Rider Information Center

The rider information center is located in the instrument cluster. All

segments will light up for 2.5 seconds at start-up.

NOTE: If the instrument cluster fails to illuminate, a battery

over-voltage may have occurred and the instrument cluster

may have shut off to protect the cluster’s electrical system. If

this occurs, take the ATV to your Polaris dealer for proper

diagnosis.

1. Gear Indicator - As the shift lever is moved, this indicates the

gear the transmission is in:

H = High Range

L = Low Range

N = Neutral

R = Reverse

P = Park

2. AWD Indicator - This

indicator illuminates

when the electrical

portion of the AWD

system is enabled.

3. Engine Hour Display Indicator

4. Service Interval/Diagnostic Mode Indicator

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

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

battery charged. A low battery warning may also occur under normal

operation if the machine is at idle and high electrical load (lights,

cooling fan, accessories) is applied. Driving at a higher RPM or

connecting a battery charger will usually clear the warning.

6. Odometer/Tachometer/Tripmeter/ Hour Meter

7. Fuel Gauge - The segments of the fuel gauge indicate the level of

fuel in the front tank only. Since use of the rear tank is

recommended for normal operation, the rear tank may already be

empty. Refuel immediately if the last segment of the fuel gauge

clears.

8. Check Engine Warning Indicator - The word HOT will display

alphanumerically when the engine is overheating. Do not continue

to operate the ATV if this warning appears or serious engine

damage could result.

9. Mode Indicator

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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 - Tachometer

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.

Mode 4 - Tachometer

The engine RPM is displayed digitally.

NOTE: Small fluctuations in the RPM from day to day may be

normal because of changes in humidity, temperature,

elevation and electrical loads.

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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.

As long as the gauge is in the diagnostic mode, the wrench icon will

remain lit.

To leave the diagnostic mode, turn the key switch off and on. Any

movement of the tires will also take the machine out of the diagnostic

mode.

To enter the diagnostics mode:

1. Turn the key switch off and wait 10 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.

4. Release the switch as soon as the display is activated.

The initial screen display 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.

Screen 1: Battery voltage

Screen 2: Tachometer

Screen 3: AWD diagnostic

This gauge indicates whether or not current is flowing through the

AWD coil (only on models with switchable AWD).

Screen 4: Gear circuit diagnostic

This screen displays the resistance value (in ohms) being read at the

gear switch input of the gauge.

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FEATURES

Instrument Cluster

Rider Information Center

Diagnostic Mode

Screen 5: 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 set at

50 hours. 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.

Screen 6: Miles/Kilometers toggle

The display in the tripmeter and odometer can be changed to display

either kilometers or miles. The current display mode will be shown as

KM or MP. To change, hold in the mode button until the letters flash,

then press and release the button once. When the display stops

flashing, the mode has been set.

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OPERATION

Fuel Safety

WARNING

Gasoline is highly flammable and explosive under certain

conditions.

S Always exercise extreme caution whenever handling gasoline.

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

ventilated area.

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

area where refueling is performed or where gasoline is stored.

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

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

with soap and water and change clothing.

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

Engine exhaust fumes are poisonous and can cause loss of

consciousness or death in a short time.

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

WARNING

The engine exhaust from this product contains chemicals known

to cause cancer, birth defects or other reproductive harm.

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

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OPERATION

Break-In Period

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.

CAUTION

Mixing brands or using a non-recommended oil may cause

serious engine damage. We recommend the use of Polaris

Premium 4 synthetic Oil or another 0W-40 API certified SH oil.

Never substitute or mix oil brands.

1. Fill the fuel tanks with gasoline. See page 39.

2. Check the oil reservoir level on the dipstick. See page 75. Add

oil if necessary to maintain the level between the safe and add

marks.

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

familiarize yourself with vehicle operation and handling.

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

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

on the daily pre-ride inspection checklist. See page 51.

6. Pull only light loads.

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

hours, 200 miles, or one month, whichever comes first.

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OPERATION

Pre-Ride Inspection

WARNING

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

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

to ensure it’s in proper operating condition.

Pre-Ride Checklist

Item

Remarks

See

Page

Brake system / lever travel

Brake fluid

Ensure proper operation

Ensure proper level

35, 84

Auxiliary brake

Front suspension

Rear suspension

Steering

Ensure proper operation

Inspect, lubricate if necessary

Ensure free operation

Tires

Inspect condition and pressure

Inspect, ensure fastener tightness

Wheels / fasteners

Frame nuts, bolts, fasteners Inspect, ensure tightness

Fuel and oil

Ensure proper levels

Ensure proper level

Coolant level (if applicable)

Coolant hoses (if applicable) Inspect for leaks

Throttle

Ensure proper operation

34, 111

Indicator lights / switches

Engine stop switch

Air filter, pre-filter

Air box sediment tube

Headlamp

Ensure operation

Ensure proper operation

Inspect, clean

Drain deposits whenever visible

Check operation, apply Polaris dielec-

tric grease when lamp is replaced

Brake light / tail lamp

Riding gear

Check operation, apply Polaris dielec-

tric grease when lamp is replaced

Wear helmet, goggles, protective

clothing

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OPERATION

Starting the Engine

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.

1. Place the transmission in PARK

and lock the parking brake.

2. Turn the fuel valve on.

3. Sit on the vehicle and pull the

choke knob (1) out until it stops.

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.

4. Turn the engine stop switch to RUN.

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

5. 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. Activate the starter for another five

seconds if necessary. Repeat this procedure until the engine starts.

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

allow proper engine warm-up.

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

When the engine idles smoothly, push the choke completely in.

CAUTION

Operating the vehicle immediately after starting could cause

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

before operating the vehicle.

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OPERATION

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

PARK.

2. Lock the parking brake. Turn the fuel valve 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 (knob 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

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

oil level could indicate the accumulation of contaminants such as water

or excess fuel 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

Driving Safely

Hauling Cargo

1/3

2/3

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

Always read and understand the load distribution warning labels on the

vehicle, and never exceed the weight capacities outlined in the

specifications section of the owner’s manual and on the safety decals.

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

2/3 on the rear rack) and mounted as low as possible. When operating

over rough or hilly terrain, reduce speed and cargo weight to maintain

stable driving conditions. Do not obstruct the headlight beam with

cargo.

Belt Life

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

belt life.

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OPERATION

Driving Safely

Hauling Cargo

WARNING

Hauling cargo improperly can alter vehicle handling and may

cause loss of control or brake instability and result in serious

injury or death. Always follow these precautions when hauling

cargo:

S REDUCE SPEED AND ALLOW GREATER DISTANCES FOR

BRAKING WHEN HAULING CARGO.

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

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

hilly terrain, reduce speed and cargo to maintain stable driving

conditions. Carrying loads on one rack only increases the

possibility of vehicle overturn.

S CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE.

Carrying loads high on the racks raises the center of gravity of

the vehicle and creates a less stable operating condition.

S SECURE ALL LOADS BEFORE OPERATING. Unsecured

loads can create unstable operating conditions, which could

result in loss of control of the vehicle.

S OPERATE ONLY WITH STABLE AND SAFELY ARRANGED

LOADS. When handling off-centered loads that cannot be

centered, securely fasten the load and operate with extra

caution. Always attach the tow load to the hitch point

designated for your vehicle.

S HEAVY LOADS CAN CAUSE BRAKING AND CONTROL

PROBLEMS. Use extreme caution when applying brakes with a

loaded vehicle. Avoid terrain or situations that may require

backing downhill.

S USE EXTREME CAUTION when operating with loads that

extend over the rack sides. Stability and maneuverability may

be adversely affected, causing the vehicle to overturn.

S DO NOT BLOCK THE FRONT HEADLIGHT BEAM when

carrying 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

Your ATV is equipped with a rear

axle that drives both rear wheels

equally at all times. This means that

the wheel on the outside of the turn

must travel a greater distance than

the inside wheel when turning and

the inside tire must slip traction

slightly. To turn, steer in the

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. Engage AWD before

wheels begin to lose

traction.

3. Maintain a high level

of alertness, reading the

trail and avoiding quick,

sharp turns, which can cause

skids.

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

and shifting your body weight forward.

CAUTION

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

while the wheels are spinning. Always allow the rear wheels to

stop spinning before engaging AWD, or engage AWD before

wheels begin to lose traction.

WARNING

Failure to exercise care when operating on slippery surfaces can

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

and serious injury or death.

Never apply the brakes during a skid. Do not operate on

excessively slippery surfaces. Always reduce speed and use

additional caution.

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OPERATION

Driving Safely

Driving Uphill

25_ Maximum

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.

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 the most dangerous type of driving encountered 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.

Familiarize yourself with operation of the auxiliary brake in the event

loss of normal service brakes occurs.

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 down the hill!

Use the K-turn to turn around.

8 ft. (2.4 m)

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OPERATION

Driving Safely

Turning Around on a Hill

1. Stop the vehicle and lock the parking brake while keeping body

weight uphill.

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

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

vehicle is pointing straight uphill.

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

5. While holding the service brake, 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 service brake, until the vehicle is on more level ground.

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OPERATION

Driving Safely

Driving Through Water

Your ATV can operate through

water with a maximum

recommended depth equal to

the bottom of the footrests (1).

Follow these procedures when

operating through water:

1. Determine water depths

and current before

crossing.

2. Choose a crossing where

both banks have gradual

inclines.

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

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

lever until braking action is normal.

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

outlined in the maintenance chart. See page 69. 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 95. 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: Your Polaris ATV is equipped with a reverse speed limiter.

The override button should be used with caution as rearward

vehicle speed is greatly increased. Do not operate at wide

open throttle. Open the throttle just enough to maintain a

desired speed.

CAUTION

Excessive throttle operation while in the speed limit mode may

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

and/or engine damage.

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OPERATION

Driving Safely

Parking on an Incline

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

these precautions:

1. Turn the engine off.

2. Place the transmission in PARK.

3. Set the parking brake.

4. Always block the rear wheels on the downhill side as shown in the

illustration.

5. Shut off the fuel supply.

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EMISSION CONTROL SYSTEMS

Noise Emission Control System

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

may affect compliance with state and local noise level requirements.

Crankcase Emission Control System

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

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

The system does not allow the blow–by gases to enter the atmosphere.

Exhaust Emission Control System

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

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

and related components must be maintained at Polaris specifications to

achieve optimal performance.

Adjustment to engine idle is the only adjustment Polaris recommends

that the operator perform. Any other adjustments should be performed

by an authorized Polaris dealer.

The emissions label is located on the recoil cover.

WARNING

The installation of devices that effectively increase exhaust

emissions beyond their legal limits will void all manufacturer

warranties and may violate laws governing the registration and

operation of this vehicle.

Spark Arrestor

Your Polaris vehicle has a spark arrestor that was tested and approved

in accordance with the USDA Forest Service Standard 5100–1C. Fed-

eral law requires that this spark arrestor be installed and functional

when the vehicle is operated on public lands.

Electromagnetic Interference

This spark ignition system complies with Canadian ICES--002.

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MAINTENANCE AND LUBRICATION

Accessories

Auxiliary power outlets provide 12V power for operating accessories

such as hand held spot lights. See your Polaris dealer.

Periodic Maintenance Chart

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

most reliable condition. Inspection, adjustment and lubrication of

important components are explained in the periodic maintenance chart.

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

inspection reveals the need for replacement parts, use genuine Polaris

parts available from your Polaris dealer.

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 intervals in the following chart are based upon average

riding conditions and an average vehicle speed of approximately 10

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

serviced more frequently.

Severe Use Definition

S Frequent immersion in mud, water or sand

S Racing or race-style high RPM use

S Prolonged low speed, heavy load operation

S Extended idle

S Short trip cold weather operation

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

weather can indicate contaminants collecting in the oil sump or

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

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

determine the cause or see your dealer.

Maintenance Chart Key

Perform these procedures more frequently for vehicles subjected to

severe use.

Emission Control System Service (California)

Have an authorized Polaris dealer perform these services.

WARNING

Improperly performing the procedures marked with a J could

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

Have an authorized Polaris dealer perform these services.

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

Item

Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar

Miles

(Km)

Steering

Pre-Ride

Make adjustments as need-

ed. See Pre-Ride Checklist

on page 51.

Front suspension

Rear suspension

Tires

Brake fluid level

Brake lever travel

Brake system

Wheels/fasteners

Frame fasteners

Engine oil level

Air filter, pre-filter

Daily

Inspect; clean often

Air box sediment

tube

Drain deposits when visible

Coolant

Daily

Check level daily, change

coolant every 2 years

Headlamp/tail

lamp

Daily

Check operation

Air filter,

main element

Weekly

Inspect; replace as needed

Recoil housing

Drain water as needed,

check often if operating in

wet conditions

Brake pad wear

10 H

Monthly

100 (160)

Inspect periodically

Battery

20 H

25 H

Monthly

200 (320)

250 (400)

Check terminals; clean; test

Inspect level; change yearly

Front gearcase oil

Rear gearcase oil

(if equipped)

Transmission oil

25 H

Monthly

250 (400)

Inspect level; change yearly

Inspect; clean if needed

Engine breather

filter (if equipped)

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

Emission Control System Service (California)

Have an authorized Polaris dealer perform these services.

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Item

Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar

Miles

(Km)

General

50 H

3 M

6 M

500 (800)

Lubricate all fittings, pivots,

cables, etc.

lubrication

Carburetor float

bowl

Drain bowl periodically and

prior to storage

Throttle Cable/

ETC Switch

Inspect; adjust; lubricate;

replace if necessary

Choke cable

Inspect; adjust; lubricate;

replace if necessary

Carburetor air

intake ducts/

flange

Inspect ducts for proper

sealing/air leaks

Drive belt

50 H

6 M

500 (800)

Inspect; adjust; replace as

needed

Cooling system

1000 (1600) Inspect coolant strength

seasonally; pressure test

system yearly

Engine oil change 100 H

6 M

1000 (1600) Perform a break-in oil

change at one month

Oil filter change

100 H

1000 (1600) Replace with oil change

1000 (1600) Inspect routing, condition

1000 (1600) Inspect; adjust

Oil tank vent hose 100 H

(if equipped)

12 M

Valve clearance

100 H

Fuel system/filter

100 H

1000 (1600) Check for leaks at tank cap,

lines, fuel valve, filter, pump,

carburetor; replace lines

every two years

Radiator

100 H

12 M

1000 (1600) Inspect; clean external

surfaces

(if applicable)

Cooling hoses

(if applicable)

1000 (1600) Inspect for leaks

Engine mounts

100 H

12 M

1000 (1600) Inspect

Exhaust muffler/

pipe

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

Emission Control System Service (California)

Have an authorized Polaris dealer perform these services.

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Item

Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar

Miles

(Km)

Spark plug

Ignition Timing

Wiring

100 H

12 M

1000 (1600) Inspect; replace as needed

1000 (1600) Inspect

1000 (1600) Inspect for wear, routing,

security; apply dielectric

grease to connectors

subjected to water, mud, etc.

Clutches (drive

and driven)

100 H

12 M

1000 (1600) Inspect; clean; replace worn

parts

Front wheel

bearings

1000 (1600) Inspect; replace as needed

Brake fluid

200 H

300 H

24 M

36 M

2000 (3200) Change every two years

3000 (4800) Clean out

Spark arrestor

Winch System

See The Basic Guide to

Winching Techniques, pro-

vided by the winch manufac-

turer.

Idle speed

Adjust as needed

Toe adjustment

Inspect periodically; adjust

when parts are replaced

Headlight aim

Adjust as needed

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

Emission Control System Service (California)

Have an authorized Polaris dealer perform these services.

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MAINTENANCE AND LUBRICATION

Lubrication Guide

Check and lubricate all components at the intervals outlined in the

Periodic Maintenance Chart beginning on page 69. Items not listed in

the chart should be lubricated at the General Lubrication interval.

Lubrication Guide Key

More often under severe use

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.

Item

Engine Oil

Lube

Method

Polaris Premium 4 Synthetic

0W40

Add to proper level on dip-

stick.

Brake Fluid

DOT 3 Only

Maintain level between fill

lines. See page 36.

Transmission Oil

Front Gearcase Oil

Rear Gearcase Oil

Polaris Premium AGL Synthetic

Gearcase Lube

See page 78.

See page 77.

See page 79.

Premium Demand Drive Hub

Fluid

Premium ATV Angle Drive Fluid

Front Prop Shaft Yoke FGrease

(Fig. 1)

Grease fittings (3 pumps

maximum).

Ball Joint (Fig. 2)

Locate fitting on back side of

struts and grease with

grease gun.

"LGrease

(Fig. 1)

(Fig. 2)

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MAINTENANCE AND LUBRICATION

Premium 4 Synthetic Lubricant

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 114 for the part numbers of Polaris 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. (-40 to

+49° C.) 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 synthetic Oil or another 0W-40 API certified SH oil.

Never substitute or mix oil brands.

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MAINTENANCE AND LUBRICATION

Oil Check

The dipstick/oil fill (1) is located on the engine on the left side of the

ATV. Do not start the engine before the oil check.

NOTE: A rising oil level between checks in cool weather driving can

indicate contaminants such as gas or moisture collecting in

the crankcase. If the oil level is over the full/safe mark,

change the oil immediately.

1. Position the vehicle on a level surface.

2. Remove the dipstick and wipe it dry

with a clean cloth.

NOTE: Lift the lever lock (2) to remove

the dipstick.

3. Reinstall the dipstick completely, but

do not lock it. The dipstick must be

completely seated.

4. Remove the dipstick

and check the oil level.

Maintain the oil level

between the SAFE

and ADD marks (3).

Do not overfill.

ADD 8 OZ

SAFE

NOTE: Due to the dipstick

entry angle into the

crankcase, the oil level

will read higher on the

bottom side of the dipstick.

Always read the level on

the upper surface (4) of

the dipstick.

5. After reinstalling the dipstick,

seat the lever lock.

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MAINTENANCE AND LUBRICATION

Oil and Filter Change

Change the oil and filter at the intervals outlined in the Periodic

Maintenance Chart beginning on page 69. Always install a new filter

when changing the oil.

1. Position the vehicle on a level surface.

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

engine.

3. Clean the area around the drain plug.

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

plug.

CAUTION

Hot oil can cause serious burns. Do not allow hot oil to touch

skin.

5. Allow the oil to drain completely.

6. Replace the sealing washer on the drain plug.

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

clean and free of burrs, nicks or scratches.

7. Reinstall the drain plug and torque to 20 ft. lbs. (27 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 o-ring on the new filter with a film of fresh engine

oil. Check to make sure the o-ring is in good condition.

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

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

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

recommended oil.

13. Place the gear selector in PARK 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. Re-check the oil level on the dipstick 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

Front Gearcase Oil

Always check and change the front gearcase oil at the intervals

outlined in the Periodic Maintenance Chart beginning on page 66.

Maintain the oil level even with the bottom of the fill hole threads (1).

Refer to the Gearcase Specifications Chart on page 80 for

recommended lubricants, capacities and torque specifications. Use of

other oils may result in improper operation of components. See page

114 for the part numbers of Polaris products.

Oil Check

1. Position the vehicle on a level surface.

2. Remove the fill plug (2) and view

the oil level.

3. Add the recommended gearcase oil

as needed to bring the level to the

bottom of the fill hole threads.

4. Reinstall the fill plug. Torque to

specification.

Oil Change

1. Position the vehicle on a level surface

and remove the fill plug.

2. Place a drain pan beneath the

gearcase, remove the gearcase drain

plug (3) located on the bottom

right-hand side, and drain the oil.

3. Clean and reinstall the drain plug.

Torque to specification.

4. Add the recommended fluid.

5. Reinstall the fill plug. Torque to

specification.

6. Check for leaks.

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MAINTENANCE AND LUBRICATION

Transmission Oil

Always check and change the

transmission oil at the intervals outlined in

the Periodic Maintenance Chart

beginning on page 69. Maintain the

transmission oil level at the bottom of

the fill plug hole (1). Refer to the

Gearcase Specifications Chart on page 80

for recommended lubricants, capacities

and torque specifications. See page 114

for the part numbers of Polaris products.

The transmission oil fill plug (2) is

located on the right side of the ATV

behind the footwell. The transmission

drain plug (3), is located on the bottom

left-hand side of the gearcase.

Oil Check

1. Remove the footwell (see page 86).

2. Remove the fill plug and check the oil level.

3. Reinstall the fill plug. Torque to specification.

4. Reinstall the footwell.

Oil Change

1. Remove the footwell (see page 86).

2. Remove the drain plug and drain the oil into a drain pan. Dispose

of properly.

3. Clean and reinstall the drain plug. Torque to specification.

4. Remove the fill plug and add the recommended fluid.

5. Reinstall the fill plug. Torque to specification.

6. Check for leaks.

7. Reinstall the footwell.

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MAINTENANCE AND LUBRICATION

Rear Gearcase Oil

The rear gearcase has two

fill plugs. The rear fill

plug is located on the rear

of the gearcase and is not

easily accessible. The side

fill plug (1) is located on the

left side of the gearcase.

Use the side fill plug when

checking or changing oil.

Always check and change

the rear gearcase oil at the

intervals outlined in the

Periodic Maintenance Chart

beginning on page 69.

Maintain the oil level (2)

even with the bottom of the side fill hole. Refer to the Gearcase

Specifications Chart on page 80 for recommended lubricants,

capacities and torque specifications. See page 114 for the part numbers

of Polaris products.

Oil Check

1. Position the vehicle on a level surface.

2. Remove the side fill plug and view the oil level through the fill

plug hole.

3. Add the recommended gearcase oil as needed.

4. Reinstall the fill plug. Torque to specification.

Oil Change

1. Place a drain pan beneath the drain and remove the drain plug.

Catch and discard used oil properly.

2. Clean and reinstall the drain plug with a new sealing washer.

Torque to specification.

3. Remove the side fill plug and add the recommended fluid.

4. Check the oil level. Maintain the oil level at the bottom of the fill

plug hole.

5. Reinstall the fill plug. Torque to specification.

6. Check for leaks.

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MAINTENANCE AND LUBRICATION

Gearcase Specification Chart

Gearcase

Lubricant

Capacity

Fill Plug

Torque

Drain Plug

Torque

Main Gearcase

(Transmission)

Premium AGL

Synthetic Gearcase

Lube

15.2 oz.

(450 ml)

14 ft. lbs.

(19.4 Nm)

14 ft. lbs.

(19.4 Nm)

Front Gearcase

Rear Gearcase

Premium Demand

Drive Hub Fluid

5 oz.

8-10 ft. lbs.

11 ft. lbs.

(15 Nm)

(150 ml) (11-13.6 Nm)

Premium ATV Angle

Drive Fluid

10 oz.

(300 ml)

Side plug

16 ft. lbs.

(21.7 Nm)

14 ft. lbs.

(19.4 Nm)

Engine Cooling System

Radiator Coolant Level

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 114 for the part numbers of Polaris

products.

NOTE: Always follow the manufacturer’s mixing recommendations

for the freeze protection required in your area.

Any time the cooling system has been drained for maintenance or

repair, replace the coolant. If the recovery bottle has run dry, the level

in the radiator should be inspected. Add coolant as needed.

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.

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MAINTENANCE AND LUBRICATION

Engine Cooling System

Radiator Coolant Level

1. Remove the bolts securing the front rack. See illustration.

2. Remove the rack.

3. Remove the pressure cap (1).

4. Using a funnel, slowly add coolant through the radiator filler neck.

5. Reinstall the pressure cap.

6. Reinstall the front rack.

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.

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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, remove the

left side panel as outlined on

page 86.

Maintain the coolant level

between the minimum and

maximum marks on the

bottle (when the fluid is

cool). Add coolant as

needed.

Cooling System Operation

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.

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.

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MAINTENANCE AND LUBRICATION

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.

Toe Alignment

WARNING

Severe injury or death can result from improper toe alignment and

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

adjustments should be performed by an authorized Polaris dealer.

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

The recommended toe alignment is 1/8″ to 1/4″ (3-6 mm) 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″ (1.5-3 mm) more than the front measurement.

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

for service.

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MAINTENANCE AND LUBRICATION

Brakes

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

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

self-adjusting.

The following checks are recommended to keep the brake system in

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

under normal operation.

WARNING

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

hygroscopic, meaning it rapidly absorbs moisture from the air.

The moisture causes the boiling temperature of the brake fluid to

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

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

always discard any unused portion.

1. Always keep brake fluid at an adequate level (see page 36).

WARNING

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

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

brake fluid at the recommended level. Do not overfill.

NOTE: Under normal operation, the diaphragm extends into the

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

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

should be replaced. Always fill the reservoir as needed

whenever the cover is loosened or removed to ensure proper

diaphragm operation. Use Polaris DOT 3 brake fluid. Do not

overfill.

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MAINTENANCE AND LUBRICATION

Brakes

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 worn to 3/64″ (.1 cm).

3/64″ (.1 cm)

Auxiliary Brake

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

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

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

footrest. The hydraulic auxiliary brake system requires no adjustment.

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

the all-wheel single lever system.

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MAINTENANCE AND LUBRICATION

Side Panel Removal

1. Remove the seat.

2. Grasp the rear of the side panel near the rear cab. With a firm

motion, pull the panel outward to disengage the side panel from the

grommet.

3. Pull the panel downward and rearward to remove it from the ATV.

4. Reinstall the side panel by reversing the removal procedure.

Footwell Removal

1. Remove the four screws (1)

on the bottom of the footwell.

2. Use a flat screwdriver or

sidecutters to remove the

plastic rivets (2) securing the

footwell to the fenders.

3. Use a phillips screwdriver

and wrench to remove the

mudflap screws (3).

4. Remove the footwell.

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MAINTENANCE AND LUBRICATION

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 the owner’s manual.

Always use original equipment size and type when replacing tires.

Make sure the wheels are installed properly.

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

or less.

Tire Tread Depth

1/8I (3 mm)

Always replace tires when tread

depth is worn to 1/8″ (3 mm) or less.

See illustration.

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.

Wheel Removal

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

parking brake.

2. Loosen the wheel nuts slightly.

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

footrest frame.

4. Remove the wheel nuts and remove the wheel.

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MAINTENANCE AND LUBRICATION

Wheel Installation

1. Place the transmission in

PARK and lock the parking

brake.

WARNING

Improperly installed wheels

can adversely affect tire wear

and vehicle handling, which

can result in serious injury or

death. Always ensure that all

nuts are torqued to

specification. Do not service

axle nuts that have a cotter pin

installed. See your Polaris

dealer.

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

outside and the 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 to specification.

Wheel Nut Torque Specifications

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

loosened for maintenance service.

Item

Specification

27 ft. lbs. (37 Nm)

Front Wheel Nuts

Rear Wheel Nuts

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MAINTENANCE AND LUBRICATION

Filter Systems

Air Filter Service

1. Remove the seat, release the

air box cover 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.

6. Reinstall the air box cover and the seat.

Breather Filter/Hose

1. To access the breather filter (3), remove the left side panel as

outlined on page 86. The breather filter is on the hose that runs

between the engine and air box.

2. Remove the clamps and pull the filter out of the hoses.

NOTE: It’s not necessary to remove the lower hose from the engine.

3. Inspect the filter for debris. Blow gently through the filter in the

direction of the arrow to check for clogging. Replace if needed.

4. Check the hoses for cracks, deterioration, abrasion, or leaks.

Replace as needed.

5. Reinstall the filter and secure the clamps.

NOTE: The filter is effective with the arrow pointing in either

direction.

CAUTION

Operation of your vehicle without a breather filter can cause

engine damage. Always reinstall the breather filter after removing

for service.

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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. Allow lamps to

cool before servicing.

Headlight Lamp Replacement

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

pod.

2. Remove the screw from the rear of the pod.

3. Lift the pod slightly while depressing the tabs at the rear of the

pod.

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

the speedometer.

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

the connector, not on the wiring.

6. Turn the lamp counterclockwise to remove it.

7. Apply dielectric grease to the socket and install the new lamp.

NOTE: Make sure the tab on the lamp locates properly in the

housing.

8. Reassemble the pod.

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MAINTENANCE AND LUBRICATION

Lights

High Beam Adjustment

The headlight beam can be adjusted slightly upward or downward.

Use the following procedure to make the adjustment.

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

approximately 25 ft. (7.6 m) from a 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 two inches (5.1 cm) below the mark

on the wall.

NOTE: Include rider weight on the seat when measuring.

5. The adjustment knob is located on the right side of the headlight

pod. Adjust the beam to the desired position by turning the knob

either clockwise or counterclockwise.

Low Beam Adjustment

The low beam can be

adjusted slightly upward or

downward.

1. Loosen the headlamp

mounting bolt (1).

2. Tilt the headlamp

upward or downward.

3. Tighten the bolt.

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MAINTENANCE AND LUBRICATION

Lights

Headlight Housing Replacement

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

pod.

2. Lift the pod slightly while depressing the tabs at the rear of the

pod.

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

the speedometer.

4. Unplug the headlamp from the wiring harness.

5. Use a small screwdriver to remove the o-rings from the headlight

mounting tabs.

6. Pull the headlight housing up to release it from the locking tabs.

7. Lift the adjusting knob up to remove it from the locking tabs.

8. Carefully pull the assembly up and out of the pod.

9. Reverse the steps to install the new

housing and reassemble the pod.

NOTE: The distance from the

headlamp parting line to the

end of the adjustment knob

stop is 5 1/8″ (13 cm).

10. Adjust the headlight aim by

turning the adjusting knob.

5 1/8″

(13 cm)

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MAINTENANCE AND LUBRICATION

Lights

Lower Headlamp Removal / Installation

1. Turn the back of the headlight harness (1) in

a clockwise direction.

2. Pull the harness assembly out from the

headlight assembly.

3. Remove the headlamp and install

the new headlamp.

4. Install the new headlamp and harness

assembly into the headlight assembly. Turn the

headlight harness counterclockwise to secure.

Taillight/Brakelight Lamp Replacement

1. Remove the taillight lens

cover mounting screws (1).

2. Remove the lens cover (2)

and gasket.

3. Remove the lamp (3).

4. Apply dielectric grease to the

socket and install the new

lamp.

5. Test the taillight/brakelight.

6. Reinstall the gasket and lens cover.

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MAINTENANCE AND LUBRICATION

Spark Plugs

Always use the spark plugs recommended for your ATV. Refer to the

specifications section beginning on page 112 for the recommended spark

plug type and gap.

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 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, using the

recommended spark plug. Torque to 18 ft. lbs. (24 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 footrests.

2. Check the air box for any water and

dry it if water is present. Filter

replacement is required if water

intrusion is evident.

3. Turn the fuel valve off.

4. Remove the spark plug.

5. Loosen the carburetor drain screw (1).

6. Turn the engine over several times

using the electric start.

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

8. Tighten the carburetor drain screw.

9. Turn the fuel valve on.

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

procedure.

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

whether you succeed in starting it or not.

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

on page 99 for drying out the PVT.

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MAINTENANCE AND LUBRICATION

Recoil Housing

To prevent possible engine

damage, always drain the

recoil housing (1) after

operating the ATV in very

wet conditions. This should

also be done before storing

the ATV.

Water will enter the recoil

housing if the starter handle

is disengaged from the rope

guide when under water.

The drain screw is located at

the bottom of the recoil housing. Use a wrench to remove the screw.

Be sure to reinstall the screw after draining the housing.

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

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

lost if the crankcase drain is opened.

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MAINTENANCE 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 and leather work gloves. Do not stand behind or in

front of the vehicle while purging. Never run the engine in an

enclosed area. Exhaust contains poisonous carbon monoxide

gas.

Never go under the vehicle while it’s inclined.

1. Remove the arrestor clean-out

plug (1) from the bottom of the

muffler.

2. Place the transmission in PARK

and start the engine.

3. Purge carbon from the system by

momentarily revving the engine

several times.

4. If carbon is expelled, cover or plug the

exhaust outlet (2) and rap on the pipe around

the cleanout plug while revving the engine several more times.

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

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

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

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

engine is revved.

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

arrestor plug and remove the outlet cover or plug.

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MAINTENANCE 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 (11 KPH), due to the

system’s dependence on engine speed.

For example, when operating at a ground speed of 3 MPH (5 KPH) in

low range, the engine speed would be around 3000 RPM. This is well

above the engagement speed of 1200 - 1400 RPM. However, in high

range at 3 MPH (5 KPH), 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.).

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 (11 KPH)

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 (11 KPH)

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.

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MAINTENANCE AND LUBRICATION

Battery

Always keep battery terminals and connections free of corrosion. If

cleaning is necessary, remove corrosion with a stiff wire brush. Wash

with a solution of one tablespoon baking soda and one cup water.

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

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

allow cleaning solution or tap water into a conventional battery.

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.

100

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MAINTENANCE AND LUBRICATION

Battery

Battery Removal

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

remove battery cover.

2. Remove the battery vent tube.

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

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

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

Battery Installation

1. Set the battery in the battery holder.

2. Install the battery 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.

101

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MAINTENANCE AND LUBRICATION

Battery

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.

Replenishing Battery Fluid

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.

102

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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. Polaris also has a wide range of additional accessories

available for your ATV. See your Polaris dealer.

Cleaning and Storage

See page 114 for the part numbers of Polaris 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

Polaris does not recommend waxing the finish on this vehicle.

103

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MAINTENANCE AND LUBRICATION

Cleaning and Storage

Storage Tips

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

1. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel

Stabilizer to both tanks. Follow the instructions on the container for

the recommended amount.

NOTE: Carbon Clean will also reduce the possibility of bacterial growth

in the fuel system.

2. Fill the fuel tanks.

3. Operate the engine for 15-20 minutes to disperse the stabilizer

through the fuel in the tank and carburetor.

4. Switch tanks and operate for an additional 5-10 minutes.

5. Turn the fuel valve off.

6. Drain the carburetor bowl.

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

Inspect and clean or replace the breather filter.

104

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MAINTENANCE AND LUBRICATION

Cleaning and Storage

Storage Tips

Recoil Housing

Remove the recoil housing drain plug and drain any moisture.

Oil and Filter

Warm the engine and change the oil and filter.

Fluid Levels

Inspect the following fluid levels and change if necessary: front and

rear gearcases; transmission and brake fluid (change every two years or

as required if fluid looks dark or contaminated).

Fog the Engine

1. 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.

2. Reinstall the spark plug. Torque to 18 ft. lbs. (24 Nm).

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. Oil will be forced in and around

the piston rings and ring lands, coating the cylinder with a protective

film of fresh oil.

105

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MAINTENANCE AND LUBRICATION

Cleaning and Storage

Storage Tips

Inspect and Lubricate

Inspect all cables and lubricate. 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.

Battery Maintenance

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 dielectric 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. Store the battery in a cool, dry place.

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. Check the fluid level

monthly.

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.

106

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MAINTENANCE AND LUBRICATION

Chrome Wheel Care (if equipped)

Proper maintenance will protect chrome wheels from corrosion,

preserve wheel life and ensure a “like new” appearance for many years.

1. Wash chrome rims frequently. Use a mild detergent to remove any

salt, dirt, mud or grime. Never use abrasive cleaners on plated or

painted surfaces.

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

grade chrome polish.

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

polished chrome wheel. Choose a product suitable for chrome

finishes. Read and follow the product labels and instructions.

4. Chrome wheels exposed to road salt (or salt in the air in coastal

areas) are more susceptible to corrosion if not properly cleaned.

Clean chrome wheels more often if they’re exposed to salt or other

corrosive elements.

Removing Corrosion

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

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

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

outlined above.

107

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MAINTENANCE AND LUBRICATION

Chrome Wheel Care (if equipped)

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. Place the transmission in

PARK and lock the

parking brake.

3. Turn the fuel valve off

and be sure the fuel caps,

oil cap and seat are

installed securely.

4. Always tie the frame of

the ATV to the

transporting unit securely

with suitable straps or

rope. Do not attach tie

straps to the front A-arm

bolt pockets.

108

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ADJUSTMENTS

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.

Handlebars

The handlebars can be adjusted for rider preference.

WARNING

Improper adjustment of the handlebars or incorrect torquing of

the adjuster block tightening bolts can cause limited steering or

loosening of the handlebars, resulting in loss of control and

possible serious personal injury or death. Follow the adjustment

procedures exactly, or see your Polaris dealer for service.

1. Remove the upper

headlight pod.

2. Loosen the four bolts (1).

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” (3 mm) will remain at the

rear bolts.

109

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ADJUSTMENTS

Carburetor/Idle RPM

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.)

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.

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.

110

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ADJUSTMENTS

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″ (1.5-3 mm) 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.

111

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SPECIFICATIONS

Sportsman MV7

Gross Vehicle Weight

Dry Weight

1700 lbs. (771 kg)

992 lbs. (450 kg)

4.75 gal. (18 l)

Fuel Capacity, Front Tank

Fuel Capacity, Rear Tank

Towing Capacity

4.0 gal. (15 l)

1500 lbs. (681 kg)

150 lbs. (68 kg)

300 lbs. (136 kg)

Front Rack Capacity

Rear Rack Capacity

Hitch Tongue Capacity

150 lbs. (68.1 kg) (Rear rack capacity and tongue

weight not to exceed 300 lbs./136 kg)

Winch Capacity

Overall Length

Overall Width

2500 lbs. (1134 kg)

89 in. (226 cm)

48 in. (122 cm)

50 in. (127 cm)

50.75 in. (129 cm)

10.5 in. (26.7 cm)

71.5 in. (181.6 cm) unloaded

2 qts. (1.9 l)

Overall Height

Wheelbase

Ground Clearance

Minimum Turning Radius

Engine Oil Capacity

Coolant Capacity

Gearcase Oil Capacity, Front

Gearcase Oil Capacity, Rear

Engine

3.2 qts. (3 l)

5 oz. (150 ml)

10 oz. (300 ml)

EH068OLE017

683

Displacement

Bore x Stroke

80 x 68

Pilot Jet

Main Jet

157.5

Needle Jet

P-6 (829)

Jet Needle

4HB41-4

Pilot Screw

2 3/8

Alternator Output

Compression Ratio

Starting System

Carburetor

330 Watts @ 3000 rpm

9.78:1

Electric

BST 34mm Mikuni

CDI

Ignition System

Ignition Timing

Spark Plug / Gap

Lubrication System

Driving System Type

13° BTDC @ 1200 RPM

RC7YC / .035 in. (0.9 mm)

Pressurized Wet Sump

4 Wheel Independent Shaft

112

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SPECIFICATIONS

Sportsman MV7

Shift Type

Side Lever (H/L/N/R/P)

Gear Reduction - Low

Gear Reduction - Reverse

Gear Reduction - High

Drive Ratio - Front

Drive Ratio - Final

Tire Size - Front

Tire Size - Rear

Front Brake

7.49/1

5.11/1

3.05/1

3.82/1

3.10/1

25 x 8 - 12 (5 psi)

25 x 10 - 12 (5 psi)

Single-Control Hydraulic Disc

Hydraulic lock, all wheel

MacPherson Strut with 8.2” (21 cm) of travel

Progressive Rate with 8.5” (21.6 cm) of travel

Rear Spring Preload Adjust

Rear Brake

Parking Brake

Front Suspension

Rear Suspension

Shock Adjustment

Headlight

1 - Single Beam on Headlight Pod (50 w)

2 - Single Beam on Grill (27 w)

Taillights

8.26 w

26.9 w

LCD

Brake Light

Instrument Cluster

Jetting Chart

Altitude

AMBIENT

Below 40° F

+40° F and above

TEMPERATURE

Below 5° C

+5° C and above

Meters

(Feet)

0-1800

(0-6000)

162.5

157.5

1800-3700

(6000-12000)

155

150

Clutching Chart

Altitude

Shift

Weight

Drive Clutch

Spring

Driven

Clutch

Spring

Helix*

Meters

(Feet)

0-1800

(0-6000)

20-56

Blue/Green White/Yellow

EBS 41-37

PN 5631215 PN 7041157 PN 7041635 PN 5132751

1800-3700

(6000-12000)

20-54

Blue/Green White/Yellow

EBS 41-37

PN 5631214 PN 7041157 PN 7041635 PN 5132751

*EBS models require no helix / spring adjustment

113

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POLARIS PRODUCTS

Part No.

Description

Engine Lubricant

2870791

2871281

2871844

Fogging Oil (12 oz. Aerosol)

Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.)

Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (gal.)

Gearcase / Transmission Lubricants

Premium AGL Synthetic Gearcase Lube (qt.)

Premium AGL Synthetic Gearcase Lube (gal.)

Premium ATV Angle Drive Fluid (8 oz.)

Premium ATV Angle Drive Fluid (2.5 gal.)

Pump for Gallon Jug

2873602

2873603

2871653

2872276

2870465

2871654

2872277

Premium Demand Drive Hub Fluid (8 oz.)

Premium Demand Drive Hub Fluid (2.5 gal.)

Grease / Specialized Lubricants

Premium All Season Grease (3 oz. cartridge)

Premium All Season Grease (14 oz. cartridge)

Starter Drive Grease

Premium U-Joint Lube (3 oz.)

Premium U-Joint Lube (14 oz.)

Grease Gun Kit

Dielectric Grease (Nyogelt)

Chain Lube (6.25 oz. aerosol)

Chain Lube (16 oz. aerosol)

2871322

2871423

2871460

2871515

2871551

2871312

2871329

2872073

2872348

Coolant

2871323

2871534

60/40 Coolant (gal.)

60/40 Coolant (qt.)

Additives / Miscellaneous

Brake and Clutch Cleaner

Carbon Clean Plus (12 oz.)

Fuel Stabilizer (16 oz.)

DOT3 Brake Fluid

2872889

2871326

2870652

2870990

2872893

2871956

Engine Degreaser

LOCTITE 565 Thread Sealant

114

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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 62.

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.

115

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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

Refuel or switch tanks

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

Inspect and clean or replace

Drain the fuel system and refuel

Turn the fuel valve on

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

116

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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

117

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TROUBLESHOOTING

Engine Stops or Loses Power

Possible Cause

Solution

Out of fuel

Refuel or switch tanks

Kinked or plugged fuel vent line

Water present in fuel

Inspect and replace

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

Clean engine exterior

See your Polaris dealer

Engine Overheating

Possible Cause

Solution

Debris lodged in screen

Remove and clean the screen. Pull on the

top portion of the screen, then remove the

lower portion.

Plugged Radiator

Use a garden hose to flush any debris

from the radiator fins. NOTE: High pres-

sure washers can deform the radiator fins

and reduce cooling efficiency.

118

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WARRANTY

LIMITED WARRANTY

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

MONTH LIMITED WARRANTY on all components of the Polaris All

Terrain Vehicle (ATV) against defects in material or workmanship.

Polaris also gives a one year limited warranty on the final drive chain

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

charges for repair or replacement of defective parts which are covered

by this warranty. This warranty begins on the date of purchase. This

warranty is transferrable to another consumer during the 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.

119

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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.

120

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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 person at Polaris.

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

other rights which vary from state to state.

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

other warranty terms will remain in effect.

Engine Oil

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

damage. We recommend the use of Polaris engine oil for your ATV.

2. Damage resulting from the use of non-recommended lubricants may

not be covered by warranty.

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WARRANTY

Exported Vehicles

EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE

IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON

THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE

SELLING DEALER’S AUTHORIZED LOCATION.

This policy does not apply to vehicles that have received authorization

for export from Polaris Industries. Dealers may not give authorization

for export. You should consult an authorized dealer to determine this

vehicle’s warranty or service bulletin coverage if you have any ques-

tions.

This policy does not apply to vehicles registered to government offi-

cials or military personnel on assignment outside the country of the

selling dealer’s authorized location.

This policy does not apply to Safety Recalls.

How to Get Service

In the Country where your vehicle was purchased:

Warranty or Service Bulletin repairs must be done by an authorized

Polaris dealer. If you move or are traveling within the country where

your vehicle was purchased, Warranty or Service Bulletin repairs may

be requested from any authorized Polaris dealer who sells the same line

as your vehicle.

Outside the Country where your vehicle was purchased:

If you are traveling temporarily outside the country where your vehicle

was purchased, you should take your vehicle to an authorized Polaris

dealer. You must show the dealer photo identification from the country

of the selling dealer’s authorized location as proof of residence. Upon

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

form the warranty repair.

If You Move:

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

Assistance and the customs department of the destination country be-

fore you move. Vehicles importation rules vary considerably from

country to country. You may be required to present documentation of

your move to Polaris Industries in order to continue your warranty cov-

erage. You may also be required to obtain documentation from Polaris

Industries in order to register your vehicle in your new country.

122

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WARRANTY

Exported Vehicles

How to Get Service

If Purchased From A Private Party:

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

country in which the vehicle was originally purchased, all warranty

coverage will be denied.

Notice

If your vehicle is registered outside of the country where it was pur-

chased, and you have not followed the procedure set out above, your

vehicle will no longer be eligible for warranty or service bulletin cover-

age of any kind. (Vehicles registered to Government officials or mili-

tary personnel on assignment outside of the country where the vehicle

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

For questions call Polaris Customer Assistance:

United States: 1-763-417-8650

Canada: 1-204-925-7100

123

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MAINTENANCE RECORD

DATE

MILES/KM

TECHNICIAN

SERVICE PERFORMED / COMMENTS

124

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MAINTENANCE RECORD

DATE

MILES/KM

TECHNICIAN

SERVICE PERFORMED / COMMENTS

125

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MAINTENANCE RECORD

DATE

MILES/KM

TECHNICIAN

SERVICE PERFORMED / COMMENTS

126

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INDEX

Accessories . . . . . . . . . . . . . . . 69, 103

ADJUSTMENTS . . . . . . . . . . 109-111

Age Restrictions . . . . . . . . . . . . . . . 13

Air Filter Service . . . . . . . . . . . . . . . 89

All Wheel Drive . . . . . . . . . . . . . . . 43

Automatic Transmission . . . . . . . . . 40

Auxiliary Brake . . . . . . . . . . . . . . . 85

AWD . . . . . . . . . . . . . . . . . . . . . . . . 43

Electrical Switches . . . . . . . . . . . . . 33

Electromagnetic Interference . . . . . . 68

EMISSION CONTROL SYSTEMS 68

Engaging Front Gearcase . . . . . . . . 43

Engine Cooling System . . . . . . . 80-81

Engine Stop Switch . . . . . . . . . . . . 33

Equipment Modifications . . . . . . . . 17

Exhaust Emission Control System . 68

Battery . . . . . . . . . . . . . . . . . . 100-102

Battery Fluid . . . . . . . . . . . . . . . . . 102

Battery Installation . . . . . . . . . . . . 101

Battery Maintenance . . . . . . . . . . . 106

Battery Removal . . . . . . . . . . . . . . 101

Battery Storage . . . . . . . . . . . . . . . 102

Belt Life . . . . . . . . . . . . . . . . . . . . . 40

Brake Fluid . . . . . . . . . . . . . . . . 36, 38

Brake Lever . . . . . . . . . . . . . . . . . . 35

Brake, Auxiliary . . . . . . . . . . . . . . . 38

Brakelight . . . . . . . . . . . . . . . . . . . . 93

Brakes . . . . . . . . . . . . . . . . . . . . . 84-85

Break-In Period . . . . . . . . . . . . . . . . 50

Breather Filter . . . . . . . . . . . . . . . . . 89

FEATURES . . . . . . . . . . . . . . . . 41-48

Filter Systems . . . . . . . . . . . . . . . . . 89

Footwell Removal . . . . . . . . . . . . . . 86

Front Gearcase Oil . . . . . . . . . . . . . 77

Front Wheel Hub Tightening . . . . . 87

Fuel Filter . . . . . . . . . . . . . . . . . . . . 39

Fuel Requirements . . . . . . . . . . . . . 39

Fuel Safety . . . . . . . . . . . . . . . . . . . 49

Fuel Tanks . . . . . . . . . . . . . . . . . . . 39

Fuel Valve . . . . . . . . . . . . . . . . . . . . 39

Gear Selector . . . . . . . . . . . . . . . . . . 40

Gearcase Specification Chart . . . . . . 80

Handlebars . . . . . . . . . . . . . . . . . . 109

Hauling Cargo . . . . . . . . . . . . . . . 54-55

Headlight Housing Replacement . . . 92

Headlight Lamp Replacement . . . . . 90

High Beam Adjustment . . . . . . . . . . 91

High Range . . . . . . . . . . . . . . . . . . . 98

Hour Meter . . . . . . . . . . . . . . . . . . . 46

Camber and Caster . . . . . . . . . . . . 109

Carburetor/Idle RPM . . . . . . . . . . 110

Choke . . . . . . . . . . . . . . . . . . . . . . . 39

Chrome Wheel Care . . . . . . . . 107-108

Cleaning . . . . . . . . . . . . . . . . . 103-106

Clutching Chart . . . . . . . . . . . . . . . 113

Cold Weather Operation . . . . . . . . . 53

CONTROLS . . . . . . . . . . . . . . . . 33-40

Coolant Level . . . . . . . . . . . . . . . . . 82

Cooling System . . . . . . . . . . . . . . . 82

Cooling System Operation . . . . . . . 82

Corrosion . . . . . . . . . . . . . . . . . . . 107

Crankcase Emission Control System 68

I-J-K

Instrument Cluster . . . . . . . . . . . . 44-48

Jetting Chart . . . . . . . . . . . . . . . . . 113

K-Turn . . . . . . . . . . . . . . . . . . . . . . 62

Light Switches . . . . . . . . . . . . . . . . 35

Lights . . . . . . . . . . . . . . . . . . . . . 90-93

Locking the Parking Brake . . . . . . . 37

Low Beam Adjustment . . . . . . . . . . 91

Low Range . . . . . . . . . . . . . . . . . . . 98

Lower Headlamp

Diagnostic Mode . . . . . . . . . . . . . 47-48

Driving Downhill . . . . . . . . . . . . . . 61

Driving in Reverse . . . . . . . . . . . . . 66

Driving on Slippery Surfaces . . . . . 58

Driving Over Obstacles . . . . . . . . . . 65

Driving Procedures . . . . . . . . . . . . . 56

Driving Safely . . . . . . . . . . . . . . . 54-67

Driving Through Water . . . . . . . . . . 64

Driving Uphill . . . . . . . . . . . . . . . . 59

Removal/Installation . . . . . . . . 93

Lubrication Guide . . . . . . . . . . . . . . 73

127

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INDEX

Main Switch . . . . . . . . . . . . . . . . . . 33

MAINTENANCE AND

LUBRICATION . . . . . . . . 69-108

MAINTENANCE RECORD . 124-126

Making Turns . . . . . . . . . . . . . . . . . 57

Master Cylinder . . . . . . . . . . . . . . . 36

Mode/Reverse Override Switch . . . 33

Side Panel Removal . . . . . . . . . . . . 86

Sidehilling . . . . . . . . . . . . . . . . . . . 60

Spark Arrestor . . . . . . . . . . . . . . 68, 97

Spark Plug Removal and

Replacement . . . . . . . . . . . . . . 94

Spark Plugs . . . . . . . . . . . . . . . . . . . 94

SPECIFICATIONS . . . . . . . . . 112-113

Starting a Cold Engine . . . . . . . . . . 52

Starting a Warm Engine . . . . . . . . . 53

Starting the Engine . . . . . . . . . . . 52-53

Steering Assembly . . . . . . . . . . . . . 83

Stop Switch . . . . . . . . . . . . . . . . . . . 33

Storage . . . . . . . . . . . . . . . . . . 103-106

Storage Tips . . . . . . . . . . . . . . 104-106

Switches . . . . . . . . . . . . . . . . . . . . . 33

Noise Emission Control System . . . 68

Odometer . . . . . . . . . . . . . . . . . . . . 46

Oil Change . . . . . . . . . . . . . . . . . . . 76

Oil Check . . . . . . . . . . . . . . . . . . . . 75

Oil Filter Change . . . . . . . . . . . . . . 76

OPERATION . . . . . . . . . . . . . . . 49-67

Operator Safety . . . . . . . . . . . . . . 13-32

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

Tachometer . . . . . . . . . . . . . . . . . . . 46

Taillight . . . . . . . . . . . . . . . . . . . . . . 93

Throttle Cable Freeplay . . . . . . . . . 111

Throttle Lever . . . . . . . . . . . . . . . . . 34

Tires . . . . . . . . . . . . . . . . . . . . . . . . 87

Tires Run-Flat . . . . . . . . . . . . . . . . . 42

Toe Alignment . . . . . . . . . . . . . . . . 83

Transmission Oil . . . . . . . . . . . . . . . 78

Transporting the ATV . . . . . . . . . . 108

Trip Meter . . . . . . . . . . . . . . . . . . . . 46

TROUBLESHOOTING . . . . . 115-118

Turning Around on a Hill . . . . . . 62-63

Parking Brake . . . . . . . . . . . . . . . . . 37

Parking on an Incline . . . . . . . . . . . 67

Periodic Maintenance Chart . . . . 69-72

POLARIS PRODUCTS . . . . . . . . 114

Pre-Ride Inspection . . . . . . . . . . . . . 51

Premium 4 Synthetic Lubricant . . . . 74

PVT Drying . . . . . . . . . . . . . . . . . . 99

PVT System . . . . . . . . . . . . . . . . 98-99

Radiator Coolant Level . . . . . . . 80-81

Rear Gearcase Oil . . . . . . . . . . . . . . 79

Rear Spring . . . . . . . . . . . . . . . . . . 109

Recoil Housing . . . . . . . . . . . . . . . . 96

Recoil Starter . . . . . . . . . . . . . . . . . 41

Reverse Override Switch . . . . . . . . . 33

Rider Information Center . . . . . . 45-48

Run-Flat Tires . . . . . . . . . . . . . . . . . 42

VEHICLE IDENTIFICATION

NUMBERS . . . . . . . . . . . . . . . .

Vehicle Immersion . . . . . . . . . . . . . 95

WARRANTY . . . . . . . . . . . . . 119-123

WELCOME . . . . . . . . . . . . . . . . . . .

Wheel Installation . . . . . . . . . . . . . . 88

Wheel Nut Torque Specifications . . 88

Wheel Removal . . . . . . . . . . . . . . . 87

Winch Operation Switch . . . . . . . . . 33

Winch Switch, Front/Rear . . . . . . . . 33

Winches . . . . . . . . . . . . . . . . . . . . . 42

Safe Riding Gear . . . . . . . . . . . . . . . 12

SAFETY . . . . . . . . . . . . . . . . . . . . 8-32

Safety Decals and Locations . . . . . 8-11

Safety Training . . . . . . . . . . . . . . . . 13

Severe Use . . . . . . . . . . . . . . . . . . . 69

128

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