Polaris Offroad Vehicle 450 MXR User Manual

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WARNING

The engine exhaust from this

product contains chemicals known

to the State of California to cause

cancer, birth defects or other

reproductive harm.

A card containing important ATV safety information should be attached to the

owner's manual on the next page. If you cannot locate this card, or if it has been

removed, please call 1-800-342-3764 for assistance.

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Visit us at www.polarisindustries.com

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POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc.

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 con-

tained within, whether whole or in part, is expressly prohibited.

Printed in U.S.A.

2009 Outlaw 450 MXR/525 S ATV Owner's Manual

P/N 9921801

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Welcome

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

Polaris owners. We proudly produce an exciting line of utility and recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER utility vehicles

• Victory motorcycles

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Welcome

We believe Polaris sets a standard of excellence for all utility and recreational vehicles man-

ufactured 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 rec-

ommendations in this owner's manual. Your manual contains instructions for minor mainte-

nance, 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 Pure Polaris products, available through our online store at

www.purepolaris.com. Have your accessories and clothing delivered right to your door!

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Table of Contents

Introduction. . . . . . . . . . . . . . . . . . 6

Safety . . . . . . . . . . . . . . . . . . . . . 10

Features and Controls . . . . . . . . 38

Operation . . . . . . . . . . . . . . . . . . 58

Emission Control Systems . . . . . 85

Maintenance . . . . . . . . . . . . . . . . 87

Specifications . . . . . . . . . . . . . . 168

Polaris Products . . . . . . . . . . . . 172

Troubleshooting. . . . . . . . . . . . . 174

Warranty . . . . . . . . . . . . . . . . . . 186

Maintenance Log . . . . . . . . . . . 195

Index . . . . . . . . . . . . . . . . . . . . . 199

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Introduction

Safety Words and Symbols

The following signal words and symbols appear throughout this manual and on your vehicle.

Your safety is involved when these words and symbols are used. Become familiar with their

meanings before reading the manual.

The Prohibition Safety Sign indicates

The safety alert symbol indicates a potential

an action NOT to take in order to avoid

personal injury hazard.

a hazard.

WARNING

A WARNING indicates a hazardous situation

which, if not avoided, may result in death or

serious injury.

The Mandatory Action Sign indicates

an action that NEEDS to be taken to

avoid a hazard.

CAUTION

A CAUTION indicates a hazardous situation

which, if not avoided, may result in minor or

moderate injury.

NOTICE

A NOTICE indicates a situation that may result in

property damage.

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Introduction

WARNING

Failure to follow the warnings and safety precautions contained in this manual can result in severe

injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles

differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly,

even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take

proper precautions.

• Read this owner’s manual. Understand all

safety warnings, precautions and operating

procedures before operating a Polaris ATV.

Keep this manual with the ATV.

• This vehicle is an ADULT VEHICLE ONLY.

Operation is prohibited for anyone under 16

years of age.

• Never permit a guest to operate the ATV

unless the guest has read this manual and all

product labels and has completed a certified

safety training course.

• Never operate an ATV without proper

instruction. Take a training course. Purchasers

of a new Polaris ATV and their eligible family

members are entitled to take the ATV

RiderCourse^sm. Contact ATV Enrollment

Express at (800) 887-2887 or visit

www.atvsafety.org for information on

enrollment in the ATV RiderCourse^sm.

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Introduction

Vehicle Identification Numbers

Record your vehicle's identification numbers and key number in the spaces provided.

Remove the spare key and store it in a safe place. An ignition key can be duplicated only by

ordering a Polaris key blank (using your key number) and mating it with one of your existing

keys. The ignition switch must be replaced if all keys are lost.

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Introduction

Vehicle Identification Numbers

Vehicle Model Number: ________________________________________________________________________

Frame Vehicle Identification Number (1): __________________________________________________________

Engine Serial Number (2):______________________________________________________________________

Key Number (on the key): ______________________________________________________________________

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Safety

Safety Training

ATV safety training is a top priority for

Polaris. When you purchased your new

ATV, your dealer instructed you on the

authorized ATV RiderCourse^smavailable to

you and your eligible family members. This

training is included in the purchase price of

your ATV. Polaris strongly encourages you

and your age eligible family members who

will be riding the ATV to take the ATV

RiderCourse^sm.

You were also provided with printed materi-

als that explain safe operating procedures.

You should review this information on a

regular basis.

If you purchased a used Polaris ATV, you

can take the ATV RiderCourse^smby calling

ATV Enrollment Express at (800) 887-2887

or by visiting www.atvsafety.org.

Purchasers of a used Polaris ATV will be

charged for this training.

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Safety

Safety Training

A Polaris ATV is an off-road vehicle.

Familiarize yourself with all laws and

regulations concerning the operation of this

vehicle in your area.

Follow the recommended maintenance

program outlined in your owner's manual.

This program is designed to ensure that all

critical components on your vehicle are

thoroughly inspected at specific intervals.

FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety

Commission at 1-800-638-2772, or visit www.cpsc.gov, visit www.atvsafety.org, or call

Polaris at 1-800-342-3764.

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Safety

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 substan-

tial 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.

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

Safe Riding Gear

Long

Sleeves

Always wear clothing suited to the type of riding. ATV

riding requires special protective clothing for comfort and

to reduce the chance of injury.

Helmet

Wearing a helmet can prevent a severe head injury. When-

ever riding a Polaris vehicle, always wear a helmet that

meets or exceeds established safety standards.

Eye

Protection

Gloves

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

Department of Transportation (DOT) label.

Long

Pants

Approved helmets in Europe, Asia and Oceania bear the

ECE 22.05 label. The ECE mark consists of a circle sur-

rounding the letter E, followed by the distinguishing num-

ber of the country which has granted approval. The

approval number and serial number will also be displayed

on the label.

Boots

051039

0006.31

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Safety

Safe Riding Gear

Eye Protection

Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris

vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris

recommends wearing approved Personal Protective Equipment (PPE) bearing markings such

as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.

Gloves

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

Boots

The best footwear is a pair of strong over-the-calf boots with low heels.

Clothing

Always wear long sleeves and long pants to protect arms and legs. Riding pants with knee-

pads and a jersey with shoulder pads provide the best protection.

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Safety

Safety Warnings

WARNING

Failure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which

may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s

manual. See the OPERATION section of the owner’s manual for proper operating procedures.

Operator Restrictions/Age Restrictions

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

anyone under 16 years of age. This category S (Sport) ATV is a high

performance vehicle intended for off road use only, for sport-type

recreation and for competitive use by operators with advanced skills

and substantial experience.

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.

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Safety

Safety Warnings

Operating Without Instruction

Operating this ATV without proper instruction increases the risk of an

accident. The operator must understand how to operate the ATV

properly in different situations and on different types of terrain.

Beginning and inexperienced operators should complete the ATV

RiderCourse^smoffered by Polaris through the SVIA. They should then

regularly practice the skills learned in the course and the operating

techniques described in the Owner's Manual.

For more information about the ATV RiderCourse^smcontact ATV

Enrollment Express at (800) 887-2887 or visit www.atvsafety.org.

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

this manual and all product labels and has completed a certified

safety training course.

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Safety

Safety Warnings

Handling Gasoline

Exposure to Exhaust

Gasoline is highly flammable and explosive

Engine exhaust fumes are poisonous and can

cause loss of consciousness or death in a short

time. Never start the engine or let it run in an

enclosed area.

under certain conditions.

• Always exercise extreme caution whenever

handling gasoline.

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.

• Always refuel with the engine stopped, and

outdoors or in a well ventilated area.

• Do not smoke or allow open flames or sparks

in or near the area where refueling is per-

formed or where gasoline is stored.

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

neck.

• If gasoline spills on your skin or clothing,

immediately wash it off with soap and water

and change clothing.

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Safety

Safety Warnings

Failure to Inspect Before Operating

Protective Apparel

Failure to inspect and verify that the ATV is in

safe operating condition before operating

increases the risk of an accident. Always inspect

the ATV before each use to make sure it's in safe

operating condition. Always follow all inspection

and maintenance procedures and schedules

described in the owner's manual.

Operating this ATV without wearing an approved

helmet increases the risk of a serious head injury

in the event of an accident. Operating without

eye protection could result in an accident and

could increase the chance of a serious injury in

the event of an accident.

Always wear 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.

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Safety

Safety Warnings

Carrying a Passenger

Using Alcohol or Drugs

Carrying a passenger greatly reduces the

operator's ability to balance and control the ATV,

which may result in an accident or overturn.

Never carry a passenger on this ATV.

Operating the ATV after consuming alcohol or

drugs could adversely affect operator judgment,

reaction time, balance and perception. Never

consume alcohol or drugs before or while

operating an ATV.

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Safety

Safety Warnings

Operating on Pavement

Operating on Public Roads

Operating an ATV on paved surfaces (including

sidewalks, paths, parking lots and driveways)

may adversely affect the handling of the ATV and

could result in loss of control and accident or

overturn. Avoid operating the ATV on pavement.

ATV tires are designed for off-road use. If it's

unavoidable, travel slowly and avoid sudden

turns or stops.

Operating this ATV on public streets, roads or

highways could result in a collision with another

vehicle. Never operate the ATV on any public

street, road or highway, including dirt and gravel

roads. In many states it's unlawful to operate

ATVs on public streets, roads and highways.

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Safety

Safety Warnings

Operating at Excessive Speeds

Physical Control of the ATV

Operating the ATV at excessive speeds

increases the operator's risk of losing control.

Always operate at a speed that's appropriate for

the terrain, the visibility and operating conditions,

and your experience.

Removing a hand from the handlebars or feet

from the footpegs during operation can reduce

your ability to control the vehicle or cause loss of

balance and ejection from the ATV. If the

operator's foot is not firmly planted on the

footpeg, it could also contact the rear wheels.

Never remove your hands from the handlebars

while operating, and always keep both feet on

the footpegs.

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Safety

Safety Warnings

Turning Improperly

Jumps and Stunts

Turning improperly could cause loss of traction,

loss of control, accident or overturn. Always

follow proper procedures for turning as described

in the owner's manual.

Attempting wheelies, jumps and other stunts

increases the risk of an accident or overturn.

Never attempt wheelies, jumps, or other stunts.

Avoid exhibition driving.

Never turn abruptly or at sharp angles. Never

turn at high speeds. Practice turning at slow

speeds before attempting to turn at faster

speeds.

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Safety

Safety Warnings

Improper Hill Climbing

Operating on Steep Hills

Improper hill climbing could cause loss of control

or overturn. Always follow proper procedures for

climbing hills as described in the owner's

manual. See page 72.

Operating on excessively steep hills could cause

an overturn. Never operate on hills too steep for

the ATV or for your abilities. Never operate the

ATV on hills steeper than 25 degrees.

>25°

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Safety

Safety Warnings

Descending Hills Improperly

Improperly descending a hill could cause loss of control or

overturn.

• Always follow proper procedures for traveling down hills as

described in the owner's manual. NOTE: A special tech-

nique is required when braking while traveling downhill. See

page 78.

• Always descend a hill with the transmission in forward gear.

Do not descend a hill with the transmission in neutral.

• Always check the terrain carefully before descending a hill.

• Shift your weight rearward.

• Never travel down a hill at high speed.

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

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

the hill when possible.

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Safety

Safety Warnings

Crossing Hillsides

Driving on a sidehill is not recommended. Improper procedure

could cause loss of control or overturn. Avoid crossing the side

of any hill unless absolutely necessary.

If crossing a hillside is unavoidable, always follow proper

procedures as described in the owner's manual. See page 74.

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 75.

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Safety

Safety Warnings

Stalling While Climbing a Hill

Stalling, rolling backwards or improperly dismounting while climbing a

hill could cause an overturn.

Always maintain a steady speed when climbing a hill.

If all forward speed is lost

Keep body weight uphill. Apply the front brakes gradually (right

lever). When fully stopped, apply the foot brake as well, and then lock

the parking brake.

If the ATV begins rolling downhill:

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

brake while rolling backwards. Apply the front brake slowly. 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 75.

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Safety

Safety Warnings

Operating on Slippery Terrain

Failure to use extra caution when operating on excessively

rough, slippery or loose terrain could cause loss of traction,

loss of control, accident or overturn.

Do not operate on excessively rough, slippery or loose

terrain until you've learned and practiced the skills necessary

to control the ATV on such terrain.

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

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Safety

Safety Warnings

Operating in Unfamiliar Terrain

Operating Improperly in Reverse

Failure to use extra caution when operating on

unfamiliar terrain could result in an accident or

overturn. Unfamiliar terrain may contain hidden

rocks, bumps, or holes that could cause loss of

control or overturn.

Travel slowly and use extra caution when

operating on unfamiliar terrain. Always be alert to

changing terrain conditions.

Improperly operating in reverse could result in a

collision with an obstacle or person. Always

follow proper operating procedures as outlined in

this manual. See page 82.

Before shifting into reverse gear, always check

for obstacles or people behind the ATV. When it's

safe to proceed, back slowly.

Improper Tire Maintenance

Operating this ATV with improper tires or with

improper or uneven tire pressure could cause

loss of control or accident.

Always use the size and type of tires specified for

your ATV. Always maintain proper tire pressure

as described in the owner's manual and on

safety labels.

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Safety

Safety Warnings

Improper Vehicle Modifications

Operating Over Obstacles

Improper installation of accessories or

modification of the ATV may cause changes in

handling, which could cause loss of control or an

accident.

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.

Improperly operating over obstacles could cause

loss of control or overturn.

Before operating in a new area, check for

obstacles. Avoid operating over large obstacles

such as rocks and fallen trees. If unavoidable,

use extreme caution and always follow proper

operating procedures as outlined in this manual.

See page 84.

Skidding or Sliding

Skidding or sliding can cause loss of control or

overturn (if tires regain traction unexpectedly).

On slippery surfaces such as ice, travel slowly

and use extra caution to reduce the chance of

skidding or sliding.

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Safety

Safety Warnings

Operating Through Deep Water

Operating the ATV through deep or fast-flowing water could cause the tires to float, causing loss of

control or overturn. Avoid operating through deep or fast-flowing water. If it's unavoidable to enter water

that exceeds the height of the footpegs:

• Travel slowly.

• Balance your weight carefully.

• Avoid sudden movements.

• Maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make

sudden throttle changes.

• Wet brakes may have reduced stopping ability. After leaving water, test the brakes. Apply them

lightly several times while driving. The friction will help dry out the pads.

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Safety

Safety Warnings

Poor Visibility

Operating the ATV in darkness or inclement weather could result in a collision or accident, especially if

operating on a road or street. This ATV is not equipped with highway-approved lights. Operate this

vehicle off-road only. Use caution and drive at reduced speeds in conditions of reduced visibility such

as fog, rain and darkness. Clean headlights frequently and replace burned out headlamps promptly.

Improper Cargo Loading

Overloading the ATV or carrying/towing cargo may cause

changes in handling, which could cause loss of control or

an accident. Never haul cargo or tow a load with this ATV.

Never tow or pull an object behind the ATV. A wagon, sled

or other towed object does not have brakes or steering.

The object may overturn or collide with other objects.

Never exceed the stated load capacity for this ATV.

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Safety

Safety Warnings

Operating on Frozen Bodies of Water

Physical Skills

Operating on frozen bodies of water may result in

serious injury or death if the ATV and/or the

operator fall through the ice. Never operate the

ATV on a frozen body of water.

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.

Operating a Damaged ATV

Operating a damaged ATV can result in an

accident. After any overturn or accident, have a

qualified service dealer inspect the entire

machine for possible damage, including (but not

limited to) brakes, throttle and steering systems.

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Safety

Safety Warnings

Hot Exhaust Systems

Unauthorized Use of the ATV

Exhaust system components are very hot during

and after use of the vehicle. Hot components can

cause burns and fire. Do not touch hot exhaust

system components. Always keep combustible

materials away from the exhaust system. Use

caution when traveling through tall grass,

especially dry grass.

Leaving the keys in the ignition can lead to

unauthorized use of the vehicle, which could

result in an accident or overturn. Always remove

the ignition key when the vehicle is not in use.

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Safety

Safety Labels and Locations

Warning labels have been placed on the

vehicle for your protection. Read and

follow the instructions on each label

carefully. If any of the labels shown in

this manual differ from the labels on

your vehicle, always read and follow

the instructions of the labels on the

vehicle.

Discretionary/Sport ATV

Warning

Age 16

Warning

If an informational or graphic label

becomes illegible or comes off, contact

your Polaris dealer to purchase a

replacement.

Replacement safety labels are provided

by Polaris at no charge. The part num-

ber is printed on the label.

General Warning

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Safety

Safety Labels and Locations

General Warning

WARNING

ALWAYS:

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.

• use proper riding techniques to avoid vehicle

overturns on hills and rough terrain and in

turns

• avoid paved surfaces - pavement may seri-

ously affect handling and control.

NEVER operate:

• without proper training or instruction

• at speeds too fast for your skills or the condi-

tions

LOCATE AND READ OWNER'S MANUAL.

FOLLOW ALL INSTRUCTIONS AND

WARNINGS.

7175376

• on public roads - a collision can occur with

another vehicle

• with a passenger - passengers affect balance

and steering and increase risk of losing control

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Safety

Safety Labels and Locations

Age 16 Warning

WARNING

Discretionary/Sport ATV Warning

WARNING

Operating this ATV if you are under the age of 16

increases your chance of severe injury or death.

• Never operate this ATV on HILLS steeper than

25 degrees

hilly terrain, use throttle and brakes gradually

and shift weight uphill.

25°. To prevent overturn on

NEVER operate this ATV if you are under age

16.

7175374

• REVERSE operation can be dangerous even

at low speeds. Steering becomes difficult. To

prevent loss of control, avoid sudden braking

or sharp turns.

This ATV may exceed the performance of other

ATVs you may have ridden in the past. This

category S (Sport) ATV is a high performance

vehicle for off-road use only, in sport type

recreation and competitive use by operators with

advanced skills and substantial experience.

7175637

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Safety

Safety Labels and Locations

No Passenger Warning

WARNING

Tire Pressure/Load Warning

WARNING

NEVER ride as a passenger.

Improper tire pressure or overloading can cause

loss of control.

Loss of control can result in severe injury or

death.

Passengers can cause a loss of control, resulting

in SEVERE INJURY or DEATH.

7175378

• Cold tire pressure:

Front: 4.0 psi (27.6 kPa)

Rear: 4.0 psi (27.6 kPa)

• Maximum Weight Capacity 215 lbs. (98 kg)

Passenger

Warning

7175445

Tire Pressure

Warning

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Features and Controls

Main Key Switch

Engine

Stop Switch

Start

Button

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Features and Controls

Main Key Switch

The main key switch must be in the RUN position to start the engine. See page 66 for starting

procedures.

Start Button

Press the start button to engage the starter. Always release the start button promptly when the

engine starts. If the starter fails to engage, replace the blown fuse or see your Polaris dealer.

Engine Stop Switch

Move the stop switch either left or right to the OFF

position to stop the engine quickly. The engine will

not start or run when the switch is off.

Both the main switch and the engine stop switch will

shut off all electrical power to the vehicle, including

lights.

OFF

RUN

OFF

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Features and Controls

Lights

Indicator Lights

Neutral

Reverse

Hot Engine

An illuminated light in the indicator

window will alert you to the follow-

ing conditions.

• Hot engine

• Reverse gear is selected

• Neutral gear is selected

If indicator lights fail to operate,

check connections. See your Polaris

dealer for inspection of the capacitor

and voltage regulator.

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Features and Controls

Lights

Headlights

Use the headlight switch to turn the lights

on and off and to change the lights from

high beam to low beam. The key must be in

the ON position and the engine stop switch

must be in the RUN position to operate the

headlights.

Headlight Switch

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Features and Controls

Clutch Lever

The hydraulic clutch lever is located on the left handlebar.

Squeeze the clutch lever toward the handlebar to disengage

the clutch. Disengage the clutch before shifting gears.

Adjusting Knob

The clutch is self-adjusting, but lever position can be

changed to fit the operator’s hand. Turn the adjusting knob

counterclockwise to move the lever closer to the handle-

bar. Turn the adjusting knob clockwise to move the lever

away from the handlebar.

The adjustment range is limited. Never apply excessive force to the knob. Always turn the

knob manually.

Always check the lever for smooth operation before riding. If the lever does not operate

smoothly, check the fluid level at the master cylinder. See page 43.

If the lever begins to feel unresponsive, bleed the clutch system as outlined on page 138.

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Features and Controls

Clutch Fluid

The clutch fluid master cylinder is located on the

left handlebar. Check the fluid level in the reservoir

before each ride. The level should be 4mm below

the upper edge of the reservoir. Do not overfill.

Screws

Cover

Polaris recommends the use of KTM Hydraulic

Clutch Oil. Do not use brake fluid. Do not mix

clutch fluid with any other hydraulic fluids. See

page 172 for the part numbers of Polaris products.

Boot

1. Position the vehicle on a level surface.

2. Turn the handlebar until the master cylinder is

in a horizontal position.

3. Remove the two cover screws, the cover and the

rubber boot.

4. Add the recommended fluid as needed.

5. Reinstall the cover, boot and screws securely.

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Features and Controls

Throttle Lever

WARNING

Operating an ATV with sticking or improperly operating throttle controls could cause an accident. Never

start or operate an ATV that has a sticking or improperly operating throttle. Always contact your dealer

for service before operating the vehicle.

Failure to check or maintain proper operation of the throttle system can result in an accident if the

throttle lever sticks during operation. Always check the lever for free movement and return before

starting the engine. Also check occasionally during operation.

Modifications to the electronic throttle control could result in failure to perform as designed, which could

result in an accident. Do not attempt to modify the throttle control system or replace it with any after

market throttle mechanisms. Always ensure that the throttle cable is properly installed to the throttle

control.

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Features and Controls

Throttle Lever

The throttle lever is located on the right handlebar. Squeeze the lever toward the handlebar to

increase engine speed and vehicle movement.

Fuel is injected into the intake passage each time throttle is applied. Do not squeeze the throt-

tle lever while starting the engine. Do not squeeze the throttle lever when the engine is

stopped.

Engine speed returns to idle when the lever is released.

See page 141 for throttle adjustment procedures.

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 throt-

tle lever, the engine will stop, and power to the rear

wheels will cease.

Throttle Lever

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Features and Controls

Foot Brake

The foot brake operates the rear brakes. The

brake pedal is located in front of the right-hand

footpeg. If the rear wheels slide while using

the foot brake, reduce brake pedal pressure to

brake the wheels without skidding.

Check the brake fluid level frequently for the

foot brake system. The reservoir is located

under the seat. Maintain the fluid level

Foot Brake

(Rear Brake)

Footpeg

between the minimum and maximum marks.

WARNING! Aggressively applying the foot brake when backing down a hill may cause rear tipover,

which could result in serious injury or death. Never back down a hill. Use caution when applying the

foot brake. Do not aggressively apply the foot brake when going forward. The rear wheels may skid

and slide sideways, causing loss of control.

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Features and Controls

Hand Brake

The hand brake operates the front brakes. The hand

brake is located on the right handlebar. These brakes

are hydraulically activated disc type brakes. Squeeze

the brake lever toward the handlebar to engage the

front brakes.

Hand Brake

(Front Brake)

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. Always contact your

dealer for service before operating the vehicle.

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Features and Controls

Master Cylinder/Brake Fluid

WARNING

An over-full master cylinder may cause brake drag or brake lock-up, which could result in an accident.

Maintain brake fluid at the recommended level. Do not overfill.

Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs

moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can

lead to early brake fade and the possibility of brake failure, which could result in an accident. After

opening a bottle of brake fluid, always discard any unused portion.

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Features and Controls

Master Cylinder/Brake Fluid

Check the brake fluid in the master cylinder before each ride. If the fluid level is low add

DOT 4 brake fluid only. Do not overfill. See page 172 for the part numbers of Polaris prod-

ucts.

Hand Brake Fluid Level

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

handlebars so the master cylinder is level.

2. View the fluid level through the indicator window

on the side of the master cylinder.

3. Maintain the fluid level at or slightly above the

mark near the center of the sight glass. Do not

overfill.

Foot Brake Fluid Level

Fluid Level Mark

1. Position the ATV on a level surface.

2. Remove the seat and view the fluid level in the reservoir. Maintain the fluid level

between the maximum and minimum marks.

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Features and Controls

Parking Brake

1. Place the transmission in first gear.

2. Squeeze and release the brake lever two or

three times, then squeeze and hold.

3. Push the parking brake lock down to engage

the lock. Release the brake lever.

4. To release the parking brake lock, squeeze

and release the brake lever. The lock will

automatically disengage.

WARNING! Operating the ATV while the parking

brake is engaged could result in an accident. Always

check to be sure the parking brake is disengaged

before operating.

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Features and Controls

Parking Brake

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

prevent rolling. Always block the wheels on the downhill side of the ATV if leaving it parked

on a hill. Another option is to park the ATV in a sidehill position. Never depend on the park-

ing brake alone if the ATV is parked on a hill. Always block the wheels to prevent rolling.

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Features and Controls

Manual Shift

Shift Pedal

The gear shift pedal is located in front of the left-hand footpeg. One

full stroke of the pedal shifts the transmission to the next gear in the

shifting sequence. The pedal automatically returns to a horizontal

position when released.

To upshift to a higher gear, place the toe of your boot under the gear

shift pedal and raise the pedal one full stroke. See page 53.

To downshift, place your foot on the gear shift pedal and depress the

pedal one full stroke. See page 53.

Upshift

To shift into reverse, see page 54.

Downshift

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Features and Controls

Manual Shift

Shifting Gears

Always allow a cold engine to warm up

before shifting gears.

1. When starting from a stopped position,

place the transmission in neutral.

2. Squeeze and hold the brake lever. Do

not apply throttle.

3. Squeeze the clutch lever to disengage

the clutch.

7. As engine speed (RPM) increases in

first gear, simultaneously release the

throttle, disengage the clutch and shift

to second gear by raising the gear shift

pedal one full stroke. Repeat this proce-

dure to progressively upshift to addi-

tional gears. Use the same procedure to

downshift.

WARNING! Shifting without releasing the throttle

and disengaging the clutch could cause loss of

control or vehicle overturn. Always release the

throttle and fully squeeze the clutch lever while

shifting gears.

4. Depress the gear shift pedal one full

stroke to shift into first gear.

5. Release the brake lever.

6. Gradually squeeze the throttle lever

while slowly releasing the clutch lever.

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Features and Controls

Manual Shift

Reverse Lock-Out Switch

The reverse lock-out switch prevents the

operator from shifting into reverse uninten-

tionally. The switch must be manually

unlocked before shifting into reverse gear.

The lock will automatically re-engage when

the transmission is shifted out of reverse gear.

1. Place the transmission in first gear. See

page 52.

Lock-Out Lever

2. Push the lock-out lever forward toward

the handlebar to unlock the transmission.

3. Shift down into reverse gear.

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Features and Controls

Manual Shift

Deceleration

To slow or stop the vehicle, release the throttle lever and apply the brakes smoothly and

evenly. As the vehicle slows and engine speed decreases, disengage the clutch and shift to a

lower gear. Be sure engine speed has sufficiently decreased before downshifting.

WARNING! Improper use of the brakes or shifting when the engine speed is too high can cause the

tires to lose traction or stop rotating, which could result in loss of control.

NOTICE: Shifting when engine speed is too high can also cause engine and drive train damage.

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Features and Controls

Choke

The choke assists in starting a cold engine. The choke

knob is located on the left side of the carburetor. Refer

to the engine starting procedure on page 66 for correct

choke and throttle settings during starting.

Choke Knob

Fuel Tank

The fuel tank filler cap is located directly below the

handlebar. Polaris recommends the use of 91 octane or

higher fuel. Do not use E-85 fuel.

Fuel Filter

The fuel tank has an internal fuel filter. Do not attempt

to clean the fuel filter. See your Polaris dealer for service if you suspect the fuel filter is

plugged.

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Features and Controls

Fuel Valve

The fuel valve is located on the right side of the

ATV. It has three positions:

Fuel Valve

OFF: For vehicle storage and when transporting.

Turn the fuel valve off whenever the vehicle is

stored or parked.

ON: For normal operation.

RES: For reserve supply if main supply is

exhausted. There's about a 5 to 8 mile (8 to 13 km)

range on reserve gas. Always refill the gas tank as

soon as possible after using the main supply.

Always return the valve to the ON position after

refueling.

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Operation

WARNING

Failure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which

may result in serious injury or death. Read and understand all safety warnings outlined in the safety

section of this owner’s manual.

Break-In Period

The break-in period for your new Polaris ATV is the first three hours of operation, or the

time it takes to use 5-6 gallons (20 liters) of fuel. No single action on your part is as impor-

tant as following the procedures for a proper break-in. Careful treatment of a new engine and

transmission will result in more efficient performance and longer life for both.

Do not allow engine speed to exceed 7000 RPM during the break-in period. Follow the

break-in period with an additional 12 hours of cautious operation, with engine speed below

75% of capacity.

NOTICE: Failure to perform the recommended break-in maintenance can result in serious engine

damage.

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Operation

Break-In Period

Perform the following break-in and maintenance procedures carefully.

1. Fill the fuel tank with gasoline. Always

exercise extreme caution whenever han-

dling gasoline.

2. Check the oil level. Add the recom-

mended oil as needed to maintain the oil

level in the proper range. See page 99.

3. Allow the engine sufficient time to

warm up before operating.

4. Drive slowly at first. Select an open

area that allows room to familiarize

yourself with vehicle operation and

handling.

5. Excessive heat build-up during the first

three hours of operation will damage

close-fitted engine parts. Do not allow

engine speed to exceed 7000 RPM dur-

ing the first three hours of use.

6. Vary throttle positions. Do not operate

at sustained idle.

7. Perform regular checks on fluid levels,

controls and areas outlined on the daily

pre-ride inspection checklist. See page

60.

8. At the end of the break-in period (3

hours), change the engine oil and the

long and short oil filters. See page 100.

Clean the oil screen and drain plug

magnet.

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Operation

Pre-Ride Inspection

Failure to inspect and verify that the ATV is in safe operating condition before operating

increases the risk of an accident. Always inspect the ATV before each use to make sure it's in

safe operating condition.

Pre-Ride Checklist

Page

Brake systems / lever travel

Ensure proper operation

46-51

142-143

Brake fluid

Ensure proper level

Clutch lever

Check for proper operation and adjustment

Ensure proper level

Clutch fluid

Suspension, front and rear

Steering

Inspect, lubricate if necessary

Check for free operation/loose components

Inspect, ensure tightness

Frame nuts, bolts, fasteners

Fuel and oil

Ensure proper levels

56, 99

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Operation

Pre-Ride Inspection

Pre-Ride Checklist

Page

Coolant (if applicable)

Coolant hoses (if applicable)

Throttle

Ensure proper level

109

Inspect for leaks

Ensure smooth operation

Ensure operation

Indicator lights / switches

Engine stop switch

Air filter

40, 41

Ensure proper operation

Inspect, clean, replace as needed

Drain deposits when visible

112

Air box sediment tubes

Headlamp

Verify operation, apply Polaris dielectric grease to

the socket when the lamp is replaced

118

Brake light / tail lamp

Riding gear

Verify operation

Wear helmet, goggles, protective clothing

A-arm ball joints

Check freeplay. If the tire moves excessively, do not

operate. See your Polaris dealer.

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Operation

Safe Operation Practices

1. Complete the recommended safety

training before operating this vehicle.

See page 10.

2. Do not allow anyone under 16 years of

age to operate this vehicle. Do not allow

anyone with cognitive or physical dis-

abilities to operate this vehicle.

6. Use caution and drive at reduced speeds

in conditions of reduced visibility such

as fog, rain and darkness. Clean head-

lights frequently and replace burned out

headlamps promptly.

7. Never exceed the maximum weight

capacity of the vehicle. When determin-

ing the weight you are adding to the

vehicle, include the weight of the opera-

tor, accessories, loads on the racks (if

equipped) and the load on the trailer

tongue (if equipped). The combined

weight of these items must not exceed

the maximum weight capacity.

3. Never carry a passenger on this ATV.

4. Engine exhaust fumes are poisonous.

Never start the engine or let it run in an

enclosed area.

5. Operate this vehicle off-road only.

Never operate the vehicle on pavement

or on any public street, road or highway,

including dirt and gravel roads.

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Operation

Safe Operation Practices

8. Drive in a manner appropriate for your

skills and operating conditions. Never

operate at excessive speeds. Never

attempt wheelies, jumps, or other stunts.

Never remove your hands from the han-

dlebars while operating, and always

keep both feet on the footpegs.

9. Never consume alcohol or drugs before

or while operating an ATV.

10. Always use the size and type of tires

specified for your vehicle. Always

maintain proper tire pressure.

11. Never operate a damaged ATV. After

any overturn or accident, have a quali-

fied service dealer inspect the entire

machine for possible damage.

12. Never operate the ATV on a frozen

body of water.

13. Do not touch hot exhaust system com-

ponents. Always keep combustible

materials away from the exhaust sys-

tem.

14. Always remove the ignition key when

the vehicle is not in use to prevent unau-

thorized use.

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Operation

Know Your Riding Area/Tread Lightly

Familiarize yourself with all laws and regulations concerning the operation of this off-road

vehicle in your area. Respect the environment in which you ride. Find out where the desig-

nated riding areas are by contacting your Polaris dealer, a local riding club or local officials.

Help keep our trails open for recreational vehicle use. As an off-road enthusiast, you repre-

sent the sport and can set a good example (or a poor example) for others to follow. Tread

lightly. Operate with respect for the terrain, avoid littering, and always stay on the designated

trails.

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Operation

Trail Etiquette

Always practice good etiquette when riding. Allow a safe distance between your vehicle and

other vehicles operating in the same area. Communicate to oncoming operators by signaling

the number of vehicles in your group. When stopping, move your vehicle to the edge of the

trail as far as possible to allow others to pass safely.

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Operation

Starting the Engine

The engine can be started when the transmission is in neutral, or while in gear if the clutch is

disengaged. If starting a warm engine, do not use the choke.

Fuel is injected into the intake passage each time the throttle lever is depressed. Do not

depress the throttle lever while starting the engine. Do not depress the throttle lever when the

engine is stopped.

NOTICE: Operating the ATV immediately after starting could cause engine damage. Allow the engine

to warm up for several minutes before operating.

1. Shift the transmission to neutral.

Choke Knob

2. Lock the parking brake. Turn the fuel valve on.

3. Sit on the vehicle. Disengage the clutch.

4. If the engine is cold, pull the choke knob out until it

stops. Do not use the choke if starting a warm

engine.

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Operation

Starting the Engine

5. Move the engine stop switch to the RUN position. Turn the ignition key to ON.

6. If starting the engine while in gear, apply the hand brake and squeeze the clutch lever

fully to disengage the clutch. If starting the engine while in neutral, the neutral indicator

light should be on. If it isn't, disengage the clutch and shift the foot pedal to find neutral.

See page 52.

7. Do not apply throttle. Press the start button to start the engine. Activate the starter for a

maximum of five seconds. Release the start button immediately when the engine starts.

NOTICE: Excessive engagement may result in starter damage.

8. If the engine does not start, wait five seconds after releasing the start button, then acti-

vate the starter for another five seconds. Repeat until the engine starts. If the engine does

not start, review the engine troubleshooting information beginning on page 174. If all

conditions are favorable and the engine still does not start, see your Polaris dealer for

service.

9. Push the choke knob completely in. Vary engine speed slightly with the throttle to aid in

warm-up.

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Operation

Driving Procedures

1. Wear a helmet and eye protection.

2. Sit upright with both feet on the footpegs and

both hands on the handlebars.

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

4. Shift the transmission into gear. See page 52.

5. Check your surroundings and determine your

path of travel.

6. Release the parking brake.

7. Slowly depress the throttle with your right

thumb while slowly releasing the clutch lever to

begin driving.

8. Drive slowly. Practice maneuvering and using

the throttle, clutch and brakes on level surfaces.

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Operation

Making Turns

Your ATV is equipped with a solid rear axle, which drives both

rear wheels equally at all times. The wheel on the outside of the

turn travels a greater distance than the inside wheel when turn-

ing, and the inside tire slips 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 footpeg. 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 turn-

ing in reverse.

Practice making turns at slow speeds before attempting to turn

at faster speeds.

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

Never turn at high speeds.

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Operation

Driving on Slippery Surfaces

Whenever riding on slippery surfaces such as

wet trails or loose gravel, or during freezing

weather, follow these precautions:

1. Do not operate on excessively rough, slip-

pery or loose terrain.

2. Slow down when entering slippery areas.

3. Maintain a high level of alertness, reading

the trail and avoiding quick, sharp turns,

which can cause skids.

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Operation

Driving on Slippery Surfaces

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

direction of the skid and shifting your body weight forward.

Turn in

direction of

skid

Sideways

skid

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Operation

Driving Uphill

Braking and handling are greatly affected when

operating in hilly terrain. Improper procedure

could cause loss of control or overturn. When-

ever traveling uphill, follow these precautions:

1. Drive straight uphill.

2. Avoid steep hills (25° maximum).

3. Always check the terrain carefully before

ascending any hill.

4. Never climb hills with excessively slippery

or loose surfaces.

25° Maximum

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Operation

Driving Uphill

5. Keep both feet on the footpegs.

6. Shift body weight uphill.

7. Proceed at a steady rate of speed and throttle opening. Opening the throttle suddenly

could cause the ATV to flip over backwards.

8. Never back down a hill.

WARNING! Aggressively applying the foot brake when backing down a hill may cause rear tipover.

9. 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.

10. Remain alert and be prepared to take emergency action. This may include quick dis-

mounting of the vehicle.

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Operation

Driving on a Sidehill (Sidehilling)

Driving on a sidehill is not recommended. Improper procedure could cause loss of control or

overturn. Avoid crossing the side of any hill unless absolutely necessary.

If crossing a sidehill is unavoidable, follow these precautions:

1. Slow down.

2. Lean into the hill, transferring your

upper body weight uphill while keep-

ing your feet on the footpegs.

3. If the vehicle begins to slide or tip,

quickly turn the front wheel down-

hill, if possible, or dismount on the

uphill side immediately!

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Operation

Turning Around on a Hill

If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn

around:

1. Keep your body weight uphill.

2. Pull in the clutch lever and apply the front and rear brakes.

3. When completely stopped, shut off the engine. Leaving the transmission in gear, release

the clutch lever and lock the parking brake.

4. Dismount on the uphill side of the vehicle, or on the left side if the vehicle is pointing

straight uphill.

5. Staying uphill of the ATV, turn the handlebars full left.

6. Reach across the handlebar and apply the front brakes to unlock the parking brake.

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Operation

Turning Around on a Hill

7. With the front brakes applied, pull in the

clutch lever. Use the brakes to slowly allow

the vehicle to roll around to your right until

it's pointing across the hill or slightly down-

ward.

8. With the front brakes still applied, release

the clutch lever and lock the parking brake.

Remount from the uphill side, keeping body

weight uphill.

8 ft. (2.4 m)

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Operation

Turning Around on a Hill

9. Pull in the clutch lever, shift into neutral and restart the engine.

10. Release the parking brake and slowly release the clutch lever, allowing the ATV to pro-

ceed slowly. Stay in first gear, using the brakes for additional speed control if necessary,

until more level ground is reached.

11. Follow proper procedures for driving downhill. See page 78.

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Operation

Driving Downhill

When driving downhill, follow these precautions:

1. Avoid steep hills (25° maximum).

2. Shift body weight uphill. Transfer your

weight to the rear of the vehicle.

3. Drive straight downhill.

4. Slow down. Excessive speed when traveling

downhill can cause loss of control.

5. Shift to the lowest gear possible while main-

taining a safe speed.

6. Do not apply the brakes abruptly when driv-

ing downhill. Apply the foot brake slightly to

aid in slowing.

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Operation

Parking on a Hill or Incline

Avoid parking on an incline if possible. If

it's unavoidable, follow these precau-

tions:

1. Stop the engine.

2. Place the transmission in first gear.

3. Lock the parking brake.

4. Always block the rear wheels on the

downhill side. See illustration.

5. Turn the fuel valve off.

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Operation

Driving Through Water

Polaris does not recommend operating

in water deeper than the height of the

footpegs. Follow these precautions

when operating through water:

1. Determine water depth and current

before entering water.

2. Choose a crossing where the water

level is lowest and where both

banks have gradual inclines.

3. Avoid operating through deep or

fast-flowing water.

Maximum Depth

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Operation

Driving Through Water

NOTICE: Serious engine damage can result if the vehicle is not thoroughly inspected after operating

in water deeper than the footpeg level. As soon as possible, perform the inspections and

maintenance services outlined in the periodic maintenance chart beginning on page 87.

Engine oil and all grease fittings need special attention.

If the vehicle tips or overturns in water, or if the engine stops during or after operating in

water, restarting can result in serious engine damage. Transport the vehicle to your dealer

for service before restarting the engine. If this is not possible, follow the vehicle immersion

inspection and drying procedures outlined on page 126, then see your dealer for service at

the first opportunity.

4. After leaving water, test the brakes. Apply them lightly several times while driving. The

friction will help dry out the pads.

If it’s unavoidable to enter water deeper than the footpeg level:

• Proceed slowly. Avoid rocks and obstacles.

• Balance your weight carefully. Avoid sudden movements.

• Maintain a steady rate of speed. Do not make sudden turns or stops. Do not make sudden

throttle changes.

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Operation

Driving in Reverse

Follow these precautions when operat-

ing in reverse:

1. Always check for obstacles or peo-

ple behind the vehicle.

2. Always avoid backing downhill.

3. Back slowly.

4. Apply the brakes lightly for stop-

ping.

5. Avoid turning at sharp angles.

6. Never open the throttle suddenly

while backing.

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Operation

Driving in Reverse

7. Do not operate at full throttle. Use just enough throttle to maintain a desired speed.

8. Always look left, right and behind the ATV before backing.

NOTICE: Excessive throttle operation while in the speed limit mode may cause fuel to build in the

exhaust, resulting in engine popping and/or engine damage.

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Operation

Driving Over Obstacles

Follow these precautions when operating

over obstacles:

1. Always check for obstacles before oper-

ating in a new area.

2. Look ahead and learn to read the terrain.

Be constantly alert for hazards such as

logs, rocks and low hanging branches.

3. Travel slowly and use extra caution

when operating on unfamiliar terrain.

Not all obstacles are immediately visible.

4. Never attempt to operate over large

obstacles, such as rocks or fallen trees.

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Emission Control Systems

Noise Emission Control System

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

with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level require-

ments.

Operation on Public Lands in the U.S.A.

Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance

with the USDA Forest Service Standard 5100-1C. Federal law requires that this spark arres-

tor be installed and functional when the vehicle is operated on public lands.

Operation of off-road vehicles on public lands in the U.S.A. is regulated by 43 CFR

8343.1(c). Violations are subject to monetary penalties. Federal regulations can be viewed

online at www.gpoaccess.gov/ecfr/.

Crankcase Emission Control System

This engine is equipped with a closed crankcase system. Blow-by gases are forced back to

the combustion chamber by the intake system. All exhaust gases exit through the exhaust

system.

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Emission Control Systems

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 main-

tained at Polaris specifications to achieve optimal performance.

Engine idle speed is the only adjustment Polaris recommends that the operator perform. Any

other adjustments should be performed by an authorized Polaris dealer.

The emissions label is located on the front frame tube near the steering post.

Electromagnetic Interference

This spark ignition system complies with Canadian ICES-002.

This vehicle complies with the EMC requirements of European directives 97/24/EC and

2004/108/EC.

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Maintenance

Periodic Maintenance Chart

Routine inspection and service are critical to the performance and reliability of your high

performance engine. Failure to perform the recommended maintenance procedures outlined

in the Periodic Maintenance Chart will result in forfeited warranty coverage as well as

decreased performance and reliability of the vehicle. If you're unable to perform the required

service and adjustment procedures, have a qualified dealer perform these operations.

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

need for replacement parts, use genuine Polaris parts available from your Polaris dealer.

Record maintenance and service in the Maintenance Log beginning on page 195.

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Maintenance

Periodic Maintenance Chart

The recommended service intervals are based on average riding conditions. Vehicles sub-

jected to severe use must be inspected and serviced more frequently.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation

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Maintenance

Periodic Maintenance Chart

WARNING

Improperly performing the procedures marked with a Q could result in component failure and cause an

accident, which may result in serious injury or death. Always have an authorized Polaris dealer perform

these services.

Maintenance Chart Key

Perform these operations more often under severe use.

Emission-related service (Failure to conduct this maintenance will not void the

emissions warranty but may affect emissions.)

Have an authorized Polaris dealer perform these services.

z Use Polaris Premium All Season Grease or grease conforming to NLGI No. 2.

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Maintenance

Periodic Maintenance Chart

Item

Maintenance Interval

Remarks

See

Page

(whichever comes first)

Hours Calendar Fuel Used

Brake systems/brake fluid

Tires

Wheels/lug nuts

Frame fasteners

Coolant

Fuel

Engine oil

Transmission oil

Throttle

Clutch system/clutch fluid

Lights

Pre-ride

Check each day before operating

the vehicle. Make adjustments as

needed. See the Pre-Ride

Checklist.

Engine stop switch

Steering

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Maintenance

Periodic Maintenance Chart

Item

Maintenance Interval

Remarks

See

Page

(whichever comes first)

Hours Calendar Fuel Used

in gallons (liters)

Air box sediment tubes

Headlamp

Tail lamp/brake lamp

A-arm ball joint

Rear shaft assembly

Oil and filter change

Oil screen/drain plug

Idle speed

Engine mounting bolts

Valve clearance

Pre-ride

Check each day before operating

the vehicle. Make adjustments as

needed. See the Pre-Ride Check-

list.

Change the oil and filters

Clean screen and plug magnet

Check idle speed setting

Check torque

100

102

113

Break-in

5 (20)

Check; adjust

Outer clutch cover

Check 6 mounting screw torques

Perform these procedures more often for vehicles subjected to severe use

Emission-Related Service

Have an authorized Polaris dealer perform these services

Use Polaris Premium All Season Grease

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Maintenance

Periodic Maintenance Chart

Item

Maintenance Interval

Remarks

See

Page

(whichever comes first)

Hours Calendar Fuel Used

in gallons (liters)

Brake pad wear

Battery

XE Air filter

Monthly

Weekly

6 M

Inspect regularly

Check terminals; clean; test

Inspect; clean; replace as needed

Perform initial oil change after first

3 hours of operation.

143

129

112

100

Oil and filter change

26 (100)

Oil screen/drain plug

Idle speed

Engine mounting bolts

Shift lever bolt

Valve clearance

Clutches

6 M

26 (100)

52 (200)

Clean screen and plug magnet

Check; adjust as needed

Check torque

Check; adjust

102

113

Check discs for wear

Replace

122

Spark plug

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Maintenance

Periodic Maintenance Chart

Item

Maintenance Interval

Remarks

See

Page

(whichever comes first)

Hours Calendar Fuel Used

in gallons (liters)

Xz General lubrication

Carburetor float bowl

3 M

6 M

78 (300)

Lubricate all fittings, pivots,

cables, etc.

Drain bowl periodically and prior

to storage

114

QE Throttle cable/ETC switch

6 M

78 (300)

Inspect; adjust; replace as needed 141

Drive chain(s)

Inspect daily; adjust; lubricate if

needed

146

XQ Brake pad replacement

6 M

78 (300)

See your Polaris dealer

Inspect strength seasonally

108

Coolant strength

Perform these procedures more often for vehicles subjected to severe use

Emission-Related Service

Have an authorized Polaris dealer perform these services

Use Polaris Premium All Season Grease

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Maintenance

Periodic Maintenance Chart

Item

Maintenance Interval

Remarks

(whichever comes first)

Hours Calendar Fuel Used

in gallons (liters)

Xz Upper steering post (1)

6 M

Inspect; tighten fasteners; grease after

washing ATV/driving in water

Xz Front A-Arms (2)

Xz Rear axle/eccentric (3)

6 M

3 M

Inspect; tighten fasteners; grease (also

after washing ATV or driving in water)

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Maintenance

Periodic Maintenance Chart

Item

Maintenance Interval

Remarks

See

Page

(whichever comes first)

Hours Calendar Fuel Used

in gallons (liters)

Clutch springs

12 M

104 (400)

156 (600)

Check spring length (see dealer)

Check ratchet teeth for wear

Pressure test system annually

Inspect

Inspect; clean external surface;

change coolant every 2 years

Cam chain tensioner

Coolant system

Cooling system hoses

Radiator

QE Fuel system

12 M

156 (600)

Check for leaks at tank cap, lines,

fuel valve, filter, carburetor;

replace lines every two years

Cylinder and piston

Piston pin circlip groove

156 (600)

Inspect; measure; replace as

needed

Visual inspection for wear

Perform these procedures more often for vehicles subjected to severe use

Emission-Related Service

Have an authorized Polaris dealer perform these services

Use Polaris Premium All Season Grease

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Maintenance

Periodic Maintenance Chart

Item

Maintenance Interval

Remarks

(whichever comes first)

Hours Calendar Fuel Used

in gallons (liters)

Compression ring

Oil scraper ring

156 (600)

See your dealer or refer to the Dealer

Service Manual; measure ring gap and

replace if at or below service limit

Camshaft

156 (600)

Visual inspection for wear

Replace

See your dealer or refer to the Dealer

Service Manual; perform measurements;

replace as needed

Valve spring cap

Camshaft bearings

Valve springs

Valve seats/guides

Rocker arm rollers

Timing chain

Measure elongation; replace as needed

Check ratchet teeth for wear

Replace

Cam chain tensioner

Bearings (connecting rod,

balance shaft, crankshaft

main)

Crankshaft run-out

156 (600)

Measure; adjust as needed

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Maintenance

Periodic Maintenance Chart

Item

Maintenance Interval

Remarks

See

Page

(whichever comes first)

Hours Calendar Fuel Used

in gallons (liters)

Oil pressure valve

Transmission

156 (600)

Measure spring; replace as needed

Check entire transmission/bearings for

wear; replace as needed

QE Ignition Timing

Clutch fluid

QE Jet needle/needle jet

180

300

12 M

24 M

36 M

As required

Inspect; adjust as needed

Bleed as needed; change yearly

Replace

Clean out

Inspect; replace as needed

Inspect periodically; adjust when

parts are replaced

138

Brake fluid

Spark arrestor

124

Front/rear wheel bearings

Toe adjustment

144

116

Headlight aim

As required

Adjust as needed

Perform these procedures more often for vehicles subjected to severe use

Emission-Related Service

Have an authorized Polaris dealer perform these services

Use Polaris Premium All Season Grease

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Maintenance

Engine Oil Recommendations

Always check and change the engine oil at the intervals outlined in the Periodic Maintenance

Chart beginning on page 87. Polaris recommends the use of Polaris PS-4 PLUS Performance

Synthetic 2W-50 4-cycle oil or a similar oil designed for use in 4-stroke manual clutch ATV

and motorcycle applications. Do not use Polaris PS-4 Performance Synthetic 10W-40 Oil.

Always use 2W-50.See page 172 for the part numbers of Polaris products.

NOTICE: Mixing brands or using a non-recommended oil may cause serious engine damage. Always

use the recommended oil. Never substitute or mix oil brands.

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

the accumulation of contaminates such as water or excess fuel in the bottom of the crank-

case. Water in the bottom of the crankcase can lead to engine damage and must be drained.

Change the oil immediately if the oil level rises.

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Maintenance

Engine Oil Level

Check the oil level before each use of the vehi-

cle. If the engine is cold, the oil level should be

visible at the lower edge of the sight glass. If the

engine is warm, the oil level should be visible

between the 1/2 and 3/4 levels in the sight glass.

1. Position the vehicle on a level surface.

2. View the oil level through the sight glass on

the right side of the vehicle.

3. Remove the fill plug and add the recom-

mended oil as needed.

4. Reinstall the fill plug.

Sight Glass

Fill Plug

Warm Level

Cold Level

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Maintenance

Engine Oil Change

Always change the oil at the intervals outlined in the Periodic Maintenance Chart beginning

on page 87. Change the oil more frequently on vehicles subjected to severe use.

IMPORTANT: Perform the initial break-in oil change after the first three hours of operation. Always

change both oil filters and clean the oil screens whenever changing oil.

Before beginning the oil change procedure, read through the entire procedure. Be prepared to

complete the procedure entirely. Do not allow the vehicle to be without oil and filter over-

night. Always replace the oil and filters within a few hours of draining the oil.

NOTICE: If the ATV is left without oil in the system for extended periods, the oil pump may lose its

prime, which could result in engine damage.

100

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Maintenance

Engine Oil Change

1. Position the vehicle on a level surface.

2. Start the engine. Allow it to idle for two to three minutes. Stop the engine.

3. Place a drain pan beneath the crankcase. Remove the drain plug. Allow the oil to drain

completely.

CAUTION! Hot oil can cause burns to skin. Do not allow hot oil to contact skin.

4. Clean the crankcase sealing surface and the

drain plug (with magnet) thoroughly.

5. Replace the sealing ring. Reinstall the drain

plug. Torque to 15 ft. lbs. (20 Nm).

Drain

Plug

101

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Maintenance

Engine Oil Change

Cleaning the Short Oil Screen

Short Oil Screen

Plug

Front

Short Screen

O-Rings

View from bottom of vehicle

102

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Maintenance

Engine Oil Change

Cleaning the Short Oil Screen

1. Remove the short oil screen plug at the bottom of the engine.

2. Remove the short oil screen. Clean the screen components thoroughly and blow well

with low pressure compressed air.

3. Check the O-rings. If damaged, install new O-rings.

4. Reinstall the screen to the plug.

5. Lubricate the threads and reinstall the plug. Torque to 7.5 ft. lbs. (10 Nm).

103

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Maintenance

Engine Oil Change

Cleaning the Long Oil Screen

1. Remove the long screen plug, located

on the side of the engine near the engine

number.

2. Remove the oil screen. Clean the screen

thoroughly and blow with compressed

air.

Plug

3. Check the O-rings. If damaged, install

new O-rings.

4. Place the long oil screen on a pin-type

key or similar tool of about 12 inches

(300 mm) in length.

104

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Maintenance

Engine Oil Change

Cleaning the Long Oil Screen

5. Insert the tool through the opening and into the bore of the opposite engine casing wall.

Push the oil screen into the casing as far as possible. Remove the tool.

NOTICE: An improperly installed oil screen will

function poorly and result in increased

engine wear. Install the screen securely

at the angle shown in the illustration.

6. Reinstall the plug. Torque to 11 ft. lbs.

(15 Nm).

105

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Maintenance

Engine Oil Change

Changing Oil Filters

1. Place a drain pan under the engine.

2. Remove the four oil filter cover screws (1).

Remove the covers.

3. Using circle clip (snap ring) pliers, pull the

oil filter inserts (2) out of the housing.

4. Thoroughly clean the engine casing, filter

covers and sealing surfaces of the O-rings.

Check the O-rings. If damaged, install new

O-rings.

5. Fill each oil filter with oil. Install the long

filter at the front of the filter box. Install the

short filter at the rear of the box.

106

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Maintenance

Engine Oil Change

Changing Oil Filters

6. Grease the filter cover O-rings (3).

7. Reinstall the covers and the screws. Tighten

screws to 4.5 ft. lbs. (6 Nm).

8. Remove the oil fill plug (4). Add 40 oz. (1.2

liters) of the recommended engine oil (see page

98). Reinstall the fill plug.

9. Start the engine. Allow it to idle for at least one

minute to fully distribute the new oil. Stop the

engine.

10. Check for leaks at all threaded connections and

at the oil filter covers.

11. View the oil level in the sight glass. Add oil as

needed to maintain the level as recommended

(see page 99).

107

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Maintenance

Engine Cooling System

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.

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

completely drain the cooling system every two years and add a fresh mixture of antifreeze

and water.

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. Always follow

the manufacturer's mixing recommendations for the freeze protection required in your area.

Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. See

page 172 for the part numbers of Polaris products.

108

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Maintenance

Engine Cooling System

Coolant Level

The recovery bottle is located on the right side of the

vehicle under the front fender. If the fluid level is vis-

ible at the bottom of the side panel, add 6 oz. (175 ml)

of coolant.

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.

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 add-

ing coolant to the recovery bottle.

109

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Maintenance

Engine Cooling System

Radiator Coolant Level

Pressure Cap

If the recovery bottle has run dry, inspect the level in

the radiator and add coolant if necessary. The radiator

pressure cap is located on the left side of the vehicle.

CAUTION! Escaping steam can cause burns. Never

remove the pressure cap while the engine is warm or hot.

Always allow the engine to cool before removing the

pressure cap.

1. Remove the pressure cap.

2. Using a funnel, slowly add coolant as necessary

through the radiator filler neck.

3. Reinstall the pressure cap. Use of a non-standard

pressure cap will not allow the recovery system to function properly. Contact your dealer

for the correct replacement part.

110

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Maintenance

Engine Cooling System

Cooling System Bleeding

Bleeding the cooling system is required only if the system has been drained for maintenance

and/or repair. Always allow the engine to cool sufficiently before removing the radiator pres-

sure cap.

1. Remove the pressure cap.

2. Using a funnel, slowly add the recommended coolant. Fill the radiator to the bottom of

the filler neck.

3. Reinstall the pressure cap.

4. Start the engine and allow it to idle for five minutes, or until operating temperature is

reached.

5. Stop the engine.

6. After the engine has cooled, add additional coolant to refill the radiator to the bottom of

the filler neck.

7. Operate the vehicle for 20 minutes, allow the engine to cool, then recheck the coolant

level in the radiator. Add coolant as needed.

111

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Maintenance

Air Filter Systems

1. Remove the seat.

2. Release the airbox cover clips and remove the cover.

3. Remove the wing nuts securing the filter to the airbox.

4. Pull the filter assembly out of the air box. Note the placement of the rubber ring for rein-

stallation.

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

6. Apply a commercially available foam filter lubricant to the foam filter.

7. Reinstall the rubber ring properly to the filter assembly, and reinstall the filter into the air

box.

8. Secure the wing nuts and reinstall the air box cover.

9. Check the boots for cracks, deterioration, abrasion, or leaks. Replace as needed.

112

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Maintenance

Carburetor

Normal wear from engine vibrations may cause the carburetor to supply an overly rich fuel

mixture. Replace the jet needle and the needle jet after every 180 hours of operation.

Idle Speed

Carburetor idle adjustments affect engine starting behavior. A proper idle speed of 1700-

1800 RPM will result in easier starting. If idle speed is unsatisfactory, make adjustments as

outlined on page 113.

Idle Speed

1. Position the vehicle on a level surface. Lock the parking

brake. Place the transmission in neutral.

2. Start the engine and allow it to idle for five minutes, or until

operating temperature is reached.

3. Turn the idle adjusting wheel (1) until idle speed reaches

1700-1800 RPM. If idle speed is unsatisfactory after per-

forming this procedure, see your Polaris dealer for informa-

tion about jetting changes.

113

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Maintenance

Carburetor

Carburetor Draining

Drain the carburetor float bowl at the intervals outlined in the

Periodic Maintenance Chart beginning on page 87. Always

drain the bowl after exposure to wet conditions. Perform this

procedure when the engine is cool.

1. Turn the fuel valve off.

2. Place a suitable container under the carburetor to collect

drained fluid.

3. Remove the hex plug (1). Allow fluids to drain.

4. Reinstall the hex plug securely.

114

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Maintenance

Carburetor Jetting

Carburetor re-jetting can be performed to compensate for altitude and/or temperature

changes. If the vehicle is to be operated at various altitudes and temperatures, certain adjust-

ments can be made to improve its operation and driveability. Above 6000 feet (1800 m) the

engine air/fuel mixture becomes overly rich. An engine loses approximately 3% of its power

for each 1000-foot (305 m) increase in elevation. Although this power cannot be regained,

changes to the carburetor and drive system can be made to allow more efficient operation.

Contact your dealer for altitude adjustments. Your dealer has the training and special tools

required to perform these modifications.

115

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Maintenance

Lights

Headlight Adjustment

1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m)

from a flat wall.

2. Measure the distance from the floor to the center of the headlight and make a mark on

the wall at the same height.

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

25 ft. (7.6 m)

Lamp Center Height

2" (5 cm)

General Representation

116

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Maintenance

Lights

Headlight Adjustment

4. Observe the headlight aim on the wall. The most

intense part of the headlight beam should be aimed

2" (5 cm) below the mark placed on the wall.

Include rider weight on the seat when measuring.

5. Loosen the pivot screw and adjust the beam to the

desired position.

6. Tighten the screw and torque to 27 in. lbs. (3 Nm).

Pivot Screw

117

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Maintenance

Lights

Headlight Lamp Replacement

When servicing a halogen lamp, avoid touching the lamp with bare fingers. Oil from your

skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fingers do

touch a lamp, clean it with denatured alcohol.

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

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

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

3. Apply dielectric grease to the socket and install the new bulb. Rotate firmly. The bulb

must be positioned so the harness installs into the lamp at outer side.

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

118

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Maintenance

Lights

Headlight Assembly Replacement

1. Remove the front cover.

2. Remove the wire harness connector from the headlight.

3. Remove the two retaining brackets and the adjuster screw.

4. Remove the headlamp.

5. Install the new headlamp, placing it in the slots on the frame tabs. Secure the headlamp

with the retaining brackets.

6. Install the adjuster screw, leaving it loose so the headlight can be adjusted.

7. Connect the wire harness to the headlamp. Reinstall the front cover.

8. Adjust the lamp as needed (see page 116), then tighten the adjuster screw.

119

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Maintenance

Front Cab/Side Panel Removal

The front cab and side panel assembly is removed in one

piece.

Front Cover

Screws

1. Remove the seat.

2. Remove the two front cover screws and remove the front

cover.

3. Remove the eight side panel screws (four on each side).

4. Remove the fuel cap.

5. Gently pull the side panel/cab assembly upward and

rearward.

6. Unplug the key switch and the indicator panel before

removing the cab.

7. To remove a side panel from the cab, remove the corre-

sponding push pin and slide the panel forward to disen-

gage the locking tabs.

Side Panel

Screws

120

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Maintenance

Rear Cab Removal

1. Remove the seat.

2. Remove the two lower bolts (1)

on the rear fenders of the cab.

3. Remove the two bolts and

grommets (2) on the top of the

cab.

4. Remove the two bolts (3) at the

rear cab-to-front-cab joint.

5. Unplug the taillight connector.

6. Remove the cab.

121

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Maintenance

Spark Plugs

Refer to the specifications section beginning on page 168 for recommended spark plug type

and gap.

NOTICE: 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.

Spark

Plug

1. Access the spark plug at the right side of the engine.

2. Using the spark plug socket and a wrench, rotate counter-

clockwise to remove the spark plug.

CAUTION! A hot exhaust system and engine can cause burns. Wear

protective gloves when removing a spark plug for inspection.

3. After reinstalling the spark plug, torque to 14 ft. lbs. (19 Nm).

122

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Maintenance

Spark Plugs

Normal Plug

The normal insulator tip is gray, tan or light brown. There will be few combustion deposits.

The electrodes are not burned or eroded. This indicates the proper type and heat range for the

engine and the service.

The tip should not be white. A white insulator tip indicates overheating, caused by use of an

improper spark plug or incorrect carburetor/throttle body adjustments.

Wet Fouled Plug

The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a

carbon layer over the entire nose. Generally, the electrodes are not worn. General causes of

fouling are excessive oil, use of non-recommended oil, improper use of the choke, or incor-

rect carburetion adjustments.

123

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Maintenance

Spark Arrestor Clean-Out

WARNING

Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or

death. The exhaust system can get extremely hot. Do not perform service on the spark arrestor while

the system is hot. Allow components to cool sufficiently before proceeding.

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. Never

go under the vehicle while it's inclined.

124

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Maintenance

Spark Arrestor Clean-Out

To remove accumulated carbon, clean the

spark arrestor at the intervals recommended

in the Periodic Maintenance Chart beginning

on page 87.

1. Remove the retaining screw and remove

the arrestor from the end of the muffler.

Arrestor

Screen

Muffler

2. Use a non-synthetic brush to clean the

arrestor screen. A synthetic brush may

melt if components are warm. If neces-

sary, blow debris from the screen with

compressed air.

3. Inspect the screen for wear and damage.

Replace a worn or damaged screen.

Retaining

Screw

4. Reinstall the arrestor. Torque screws to

5-7 ft. lbs. (7-9 Nm).

125

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Maintenance

Vehicle Immersion

If the vehicle tips or overturns in water deeper than the footpeg level, or if the engine stops

during or after operating in water, restarting WILL result in serious engine damage. Trans-

port the vehicle to your dealer for service before restarting the engine. If this is not possible,

follow the vehicle immersion inspection and drying procedures outlined below. This proce-

dure will allow short-term operation only to drive the ATV to a trailer or towing vehicle.

Do not perform the following procedures if you don't feel completely capable, or if you sus-

pect that water has entered the fuel tank (likely if the water was deep or if the ATV over-

turned). Tow or trailer the ATV to your dealer for immediate service.

126

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Maintenance

Vehicle Immersion

1. Turn the fuel valve off.

2. Drain water from the air box and clean the air filter. See page 112.

3. Drain the carburetor bowl. See page 114.

4. Remove the spark plug. See page 122.

WARNING! Fluids will be ejected through the spark plug hole and may cause serious injury to face or

other body parts. Wear protective eyewear and stand clear of the spark plug while performing the

following steps.

5. Intermittently and briefly touch the starter button in half-second intervals to SLOWLY

rotate the engine three or four times. Fluids will eject from the spark plug hole.

(continued on following page)

127

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Maintenance

Vehicle Immersion

6. Press and hold the starter button for 10 second intervals for about one minute or until

water vapor is no longer ejecting from the spark plug hole.

7. Check the oil level. If the level is higher than the pre-ride inspection level, water has

entered the crankcase. Do not start the engine. Transport the vehicle to your dealer for

inspection and service. If the oil level is unchanged from the pre-ride inspection level,

replace the spark plug, start the engine and move the ATV promptly to a trailer or towing

vehicle.

NOTICE: If water isn't removed promptly from a submerged ATV, rust will form in precision

components, gears, bearings, the cylinder and other areas and result in serious engine

damage. Always see your dealer promptly after an ATV has been submerged.

128

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Maintenance

Battery

WARNING

Improperly connecting or disconnecting battery cables can result in an explosion and cause serious

injury or death. When removing the battery, always disconnect the negative (black) cable first. When

reinstalling the battery, always connect the negative (black) cable last.

The sealed battery is already filled with electrolyte and has been sealed and fully charged at

the factory. Never pry the sealing strip off or add any other fluid to this battery.

Keep the battery terminals and connections free of corrosion. If cleaning is necessary,

remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking

soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat

the terminals with dielectric grease or petroleum jelly.

129

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Maintenance

Battery Storage

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

from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place.

Check battery voltage each month during storage and recharge as needed to maintain a full

charge.

Battery Removal

1. Remove the rear cab (see page 120).

2. Disconnect the hold-down strap securing the battery in position.

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

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

5. Lift the battery out of the ATV.

130

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Maintenance

Battery Installation

Always install a fully charged battery. 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. If

recharging is necessary, use a .5 amp battery charger.

1. Place the battery in the battery holder.

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

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

4. Attach the hold-down strap.

5. Reinstall the rear cab.

6. Verify that cables are properly routed.

131

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Maintenance

Battery Charging (Sealed Battery)

On a sealed battery, the sealing strip cannot be removed. Use a voltmeter or multimeter to

measure DC voltage. A fully charged battery will register 12.8 V or higher. If the voltage is

less than 12.8 volts, recharge the battery.

WARNING! An overheated battery could explode, causing severe injury or death. Always watch

charging times carefully. Stop charging if the battery becomes very warm to the touch. Allow it to cool

before resuming charging.

The battery may be recharged without

removing it from the vehicle. Attach cables

in the following order:

1. Solenoid Lead

2. Negative (-)

Terminal

1. Attach the positive (+) cable clamp to

the solenoid lead (directly wired to the

battery).

2. Attach the negative (-) cable clamp to

the negative (-) battery terminal.

132

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Maintenance

Battery Charging (Sealed Battery)

The Polaris Battery Tender battery charger can be left connected during the storage period

and will automatically charge the battery if the voltage drops below a pre-determined point.

If the battery fails to recharge during vehicle operation, check voltage regulator connections.

See your Polaris dealer for inspection of the voltage regulator and generator.

When using an automatic charger such as the Polaris Battery Tender, refer to the manufac-

turer's instructions for recharging. When using a constant current charger, use the guidelines

on the following page for recharging.

133

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Maintenance

Battery Charging (Sealed Battery)

Always verify battery condition before and 1-2 hours after the end of charging.

Charge Time

(Using constant current

charger @ standard amps

specified on top of battery)

State of

Charge

Voltage

Action

100%

12.8-13.0 volts

12.5-12.8 volts

None, check at 3 months from

date of manufacture

May need slight charge, if no

charge given, check in 3

months

None required

3-6 hours

75%-100%

50%-75%

25%-50%

12.0-12.5 volts

11.5-12.0 volts

Needs charge

5-11 hours

At least 13 hours, verify

state of charge

0%-25%

11.5 volts or less

Needs charge with desulfating

charger

At least 20 hours

134

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Maintenance

Tires

WARNING

Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed

tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Always

follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle.

Always use original equipment size and type when replacing tires. Always ensure that all nuts are

torqued to specification.

Tire Tread Depth

Always replace tires when tread depth is

worn to 1/8" (3 mm) or less.

1/8" (3 mm)

135

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Maintenance

Wheel Nut Torque Specifications

Check the wheel nut torques occasionally and when they've been loosened for maintenance.

Bolt Location & Size

Torque Specification

Front 3/8"

Rear 3/8"

30-35 ft. lbs. (40-47 Nm)

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 gear. Lock the parking brake.

2. Loosen the wheel bolts slightly.

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

4. Remove the wheel nuts and remove the wheel.

136

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Maintenance

Wheel Installation

1. Place the transmission in gear. Lock the parking

brake.

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

stem toward the outside and rotation arrow on the

tire pointing toward forward rotation. Never

install the rim with the valve stem to the inside of

the vehicle.

3. Install the wheel bolts and finger tighten them.

4. Lower the vehicle to the ground.

Valve

Stem

5. Securely tighten the bolts to specification. See

page 136.

137

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Maintenance

Clutch System Bleeding

Always bleed the clutch system at the intervals out-

lined in the Periodic Maintenance Chart beginning on

page 87. Always bleed the clutch system any time the

clutch lever feels unresponsive.

Always use the recommended fluid when bleeding

the clutch system. See page 43.

1. Position the vehicle on a level surface. Turn the

handlebar until the master cylinder is in a hori-

zontal position.

2. Remove the two cover screws, the cover and the

rubber boot.

3. Fill a bleeder syringe (1) with the recommended

hydraulic clutch oil.

138

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Maintenance

Clutch System Bleeding

4. Remove the bleeder screw (2) from the slave cylinder.

5. Press fluid into the system until the fluid runs out of the hole (3) in the master cylinder

without producing bubbles. Extract fluid from the master cylinder during the process to

prevent overflowing.

6. When finished, remove the bleeder syringe.

7. Reinstall the bleeder screw.

8. Add or remove fluid as needed to maintain the level 4mm below the top edge of the mas-

ter cylinder reservoir.

9. Reinstall the cover, boot and screws securely.

139

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Maintenance

Throttle Lever Freeplay

Periodically check throttle lever freeplay.

Maintain freeplay between 1/16" and 1/8"

(1.5 - 3 mm).

If adjustments are needed, use the procedure

on page 141.

1/16" - 1/8"

(1.5 - 3 mm)

140

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Maintenance

Throttle Cable Freeplay Adjustment

WARNING

Improper adjustment of throttle cable freeplay can result in loss of control, which could result in serious

injury or death. Polaris recommends that this procedure be performed by a Polaris dealer to ensure

that it's done correctly. Mechanically knowledgeable persons who perform this procedure must follow

the adjustment procedures exactly.

1. Locate the throttle cable at the handlebar.

Locking Nut

Sleeve

2. Slide the boots off the inline cable adjuster

sleeve and loosen the locking nut.

3. Turn the adjuster until 1/16" to 1/8" (1.5-3 mm)

freeplay is achieved at the thumb lever. While

adjusting freeplay, be sure to flip the throttle

lever back and forth.

Boot

4. Tighten the locknut and slide the boots over the cable adjuster until they touch at the

midpoint of the adjuster.

141

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Maintenance

Brakes

Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the

fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm

should be replaced. To ensure proper diaphragm operation, always fill the reservoir as

needed whenever the cover is loosened or removed. Do not overfill.

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

serious injury or death. Maintain brake fluid at the recommended level. Do not overfill.

Both brakes are self-adjusting, but the following checks are recommended to keep the brake

systems in good operating condition. Check more often if brakes are used heavily under nor-

mal operation.

142

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Maintenance

Brakes

1. Always maintain brake fluid at the recommended level. See

pages 48-49.

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.

6. Inspect the rear brake disc spline and pad wear surface for

excessive wear. Pads should be changed when worn to 3/64"

(1 mm).

3/64" (1 mm)

143

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Maintenance

Toe Alignment

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

designed for a neutral toe setting.

WARNING! Severe injury or death can result from improper toe alignment and adjustment. Do not

attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized

Polaris dealer.

1. Position the vehicle on a level surface.

2. Place the handlebars in a straight-ahead position. Use tie straps to secure the handlebars

to the rear grab bar so they can't move.

144

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Maintenance

Toe Alignment

3. Tie a length of string between two stands as

shown in the illustration. Position the stands so

that the string is flush with the side of the rear

tire. If available, you may use a long straight-

edge instead of string.

Stand

4. Measure the distance from the string to the rim

at the front (1) and rear (2) of the front rim.

The rear measurement should be between 0"

and 1/16" (0-1.5 mm) more than the front mea-

surement.

String

5. Repeat the measurement procedure on the

other side of the vehicle.

6. If you discover improper alignment, see your

Polaris dealer for service.

145

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Maintenance

Chain Tension Inspection

Check the amount of chain slack by moving the

vehicle slightly forward to remove slack at the top

side of the chain.

NOTICE: Never adjust or operate the vehicle with the

rear drive chain too loose or too tight. Severe

damage to the transmission and drive

components can result. Chain tension must be

inspected with the swing arm in the position

shown in the illustration so that the axle, swing

arm pivot and drive sprocket are aligned

horizontally (2).

The chain has a press-on master link. A chain tool

must be used if it's necessary to remove the chain

for service.

146

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Maintenance

Chain Tension Inspection

1. Collapse the suspension with an adjustable (buckle type) trailer tie down strap (1). Fas-

ten the strap around the axle and rear bumper tube.

2. Tighten the strap until a straight line (2) can be drawn from the axle to the transmission

output shaft, intersecting the swing arm pivot. This establishes the tightest chain posi-

tion.

3. At the center point of the chain (3) deflection should be 1/4" - 3/8" (6-9 mm). Use the

procedure on the following page if the chain needs adjustment.

147

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Maintenance

Chain Tension Adjustment

1. Loosen the two eccentric locking bolts. Refer to the illustration on the following page.

2. Insert a pin punch into the eccentric axle housing.

3. Roll the vehicle slightly to adjust chain slack to the proper dimension.

4. Tighten the eccentric locking bolts to 35 ft. lbs. (47.5 Nm).

148

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Maintenance

Chain Tension Adjustment

Step 2

Proper splicelink clip

opening position

Step 1

149

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Maintenance

Handlebar Adjustment

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. Follow the adjustment

procedures exactly, or see your Polaris dealer for service.

The handlebars can be adjusted for rider preference.

Loosen

bolts

1. Loosen the four handlebar bolts.

2. 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.

3. Torque the two front bolts to 10-12 ft. lbs. (14-16

Nm), then torque the two rear bolts. A gap of up

to 1/8" (3 mm) will remain at the rear bolts.

150

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Maintenance

Steering Inspection

Check the steering assembly periodically for loose nuts and bolts. If loose nuts and bolts are

found, or if you notice any freeplay in the steering post, see your Polaris dealer for service

before operating the vehicle.

Camber and Caster

The camber and caster are non-adjustable.

151

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Maintenance

Suspension Settings

Use a flat-blade screwdriver to make damping adjustments. When the adjuster screw is

turned clockwise until it stops, the damping is in the fully closed position.

Rear Shock (Standard and Limited Edition)

Setting

Compression Damping

Rebound Damping

Softest

Factory

Firmest

20 clicks from closed

10 clicks from closed

2 clicks from closed

24 clicks from closed

16 clicks from closed

2 clicks from closed

Front Shock (Limited Edition)

Setting

Compression

Softest

Factory

Firmest

20 clicks from closed

10 clicks from closed

2 clicks from closed

152

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Maintenance

Front Suspension

Compression Damping (Limited Edition)

To adjust the front suspension compression damping, use the adjustment procedures outlined

for the rear suspension compression damping on page 157.

Spring Preload

The front suspension preload may be adjusted to suit different riding conditions and operator

weight. See page 154.

153

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Maintenance

Front Suspension

Spring Preload

1. Raise and safely support the front of the vehicle off the

ground to allow the suspension to fully extend.

2. Loosen the jam nut and back it away from the adjusting

ring.

3. Turn the adjusting ring to the left (1) to increase preload

for a stiffer ride. Turn the adjusting ring to the right (2) to

decrease preload for a softer ride. See Suspension Set-

tings on page 152.

Adjusting

Ring

WARNING! Uneven adjustment may cause poor handling of the

ATV, which could result in an accident. Always adjust both the left

and right spring preloads equally or have your Polaris dealer

perform the adjustments.

4. Tighten the jam nut firmly against the adjuster ring.

154

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Maintenance

Rear Suspension

Jam

Nut

The rear suspension spring preload, shock rebound damping

and shock compression damping may be adjusted to suit

different riding conditions and operator weight.

Spring Preload

1. Raise and safely support the rear of the vehicle off the

ground to allow the suspension to fully extend.

2. Loosen the jam nut and back it away from the adjusting

ring.

3. Turn the adjusting ring to the left (1) to increase pre-

load. Turn the ring to the right (2) to decrease preload.

See Suspension Settings on page 152.

Adjusting

Ring

4. Tighten the jam nut firmly against the adjuster ring.

155

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Maintenance

Rear Suspension

Rebound Damping

Use a flat-blade screwdriver to make damping adjustments.

The rebound damping is factory set at 16 clicks from fully

closed. See Suspension Settings on page 152.

1. Locate the rebound damping clicker drum between the

lower spring seat and the lower shock mount.

2. Turn the clicker counter-clockwise (1) to decrease the

rebound damping. Turn the clicker clockwise (2) to

increase rebound damping.

Clicker

156

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Maintenance

Rear Suspension

Compression Damping

Use a flat-blade screwdriver to make damping adjust-

ments. The factory setting is at 10 clicks from fully

closed. See Suspension Settings on page 152.

The compression damping clicker is located on top of

the shock reservoir, under the right rear fender.

Clicker

1. Turn the clicker clockwise (1) to increase compres-

sion damping.

2. Turn the clicker counter-clockwise (2) to decrease

compression damping.

157

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Maintenance

Cleaning

Keeping your vehicle clean will not only improve its appearance but it can also extend the

life of various components.

NOTICE: High water pressure may damage components. Polaris recommends washing the vehicle by

hand or with a garden hose, using mild soap.

Certain products, including insect repellents and chemicals, will damage plastic surfaces.

Do not allow these types of products to contact the vehicle.

Washing the Vehicle

The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild

soap and water.

1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts

last.

2. Rinse with clean water frequently.

3. Dry surfaces with a chamois to prevent water spots.

158

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Maintenance

Cleaning

Washing the Vehicle

Washing Tips

• Avoid the use of harsh cleaners, which can scratch the finish.

• Do not use a power washer to clean the vehicle.

• Do not use medium to heavy duty compounds on the finish.

• Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and

pads may contain dirt particles that will scratch the finish.

159

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Maintenance

Cleaning

Washing the Vehicle

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

caution. The water may damage components and could remove paint and decals. If warning

and safety labels are damaged, contact your Polaris dealer for free replacement. Avoid direct-

ing the water stream at the following items:

• Wheel bearings

• Brakes

• Electrical components and wiring

• Transmission seals

• Cab and body panels

• Labels and decals

Grease all zerk fittings immediately after washing. Allow the engine to run for a while to

evaporate any water that may have entered the engine or exhaust system.

160

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Maintenance

Polishing

Polaris recommends the use of common household aerosol furniture polish for polishing the

finish on your Polaris vehicle. Follow the instructions on the container.

Polishing Tips

• Avoid the use of automotive products, some of which can scratch the finish of your vehi-

cle.

• Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and

pads may contain dirt particles that will scratch the finish.

161

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Maintenance

Storage

NOTICE: Starting the engine during the storage period will disturb the protective film created by

fogging and damage could occur. Never start the engine during the storage period.

Exterior

Make necessary repairs and clean the vehicle as recommended. See page 158.

Battery Storage

Refer to pages 129-134 for battery storage and battery charging procedures.

162

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Maintenance

Storage

Engine Oil

Change the oil and both filters. Clean the oil screens. See page 100.

Air Filter / Air Box

Inspect and clean (or replace) the air filter. Clean the air box. Drain the sediment tube.

Fluid Levels

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

beginning on page 87.

• Transmission Oil

• Engine Oil

• Coolant (test strength/fill)

• Brake Fluid

• Clutch Fluid

163

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Maintenance

Storage

Stabilize the Fuel

1. Fill the fuel tank with fuel.

2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instruc-

tions on the container for the recommended amount. Carbon Clean removes water from

fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and

exhaust systems. It also prevents bacterial growth and promotes better starting after the

storage period.

3. Start the engine and allow it to run for 15-20 minutes so the stabilizer can disperse

through the fuel in the tank and carburetor.

4. Stop the engine. Turn the fuel valve off.

5. Start the engine. Allow the engine to operate until it stops.

6. Drain the carburetor bowl. See page 114.

7. Remove the spark plug. Pour approximately 5 cc of engine oil into the cylinder through

the opening. Using the start button, rotate the engine several times to distribute the oil

onto the cylinder walls. Reinstall the spark plug. Torque to specification.

164

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Maintenance

Storage

Lubricate

Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Main-

tenance Chart beginning on page 87.

Storage Area/Covers

1. Make sure tire pressure is at specification.

2. Be sure the storage area is well ventilated.

3. Using suitable supports under the frame, raise the vehicle slightly so that the tires are not

touching the ground.

4. Cover the vehicle with an appropriate cover. Do not use plastic or coated materials. They

do not allow enough ventilation to prevent condensation, and may promote corrosion

and oxidation.

165

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Maintenance

Transporting the ATV

1. Stop the engine.

2. Place the transmission in first gear.

3. Lock the parking brake.

4. Remove the key to prevent loss during transporting.

5. Secure the fuel cap, oil cap and seat.

6. Turn the fuel valve off.

7. Always tie the frame of the ATV to the transporting unit securely with suitable straps or

rope.

166

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Maintenance

Transporting the ATV

167

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Specifications

Outlaw 450 MXR

Max. Weight Capacity

Dry Weight

Fuel Capacity

Overall Length

Overall Width

Overall Height

215 lbs./98 kg

360 lbs./163 kg

3.1 gal./11.8 l

71.5 in./182 cm

47 in./119 cm

45 in./114 cm

50.5 in./128 cm

5 in./13 cm

Pilot Jet

Main Jet

Clip Position

Jet Needle

Alternator Output

Compression Ratio

Starting System

Carburetor

Ignition System

Ignition Timing

#45

#138

OBDVR

200 w @ 3000 RPM

11:1

Electric

Keihin FCR-MX 39mm

CDI

25° +/- 3° @ 3500 RPM in

neutral

Wheelbase

Ground Clearance

Min. Turning Radius

Engine Oil Capacity

67 in./170 cm

1.7 qts./1.6 l

Coolant Capacity

Engine

Displacement

Bore x Stroke

2.25 qts./2.1 l

ES45KLE

448 cc

Spark Plug Type

Spark Plug Gap

Lubrication System

NGK DCPR8E

0.6 mm / .024 in.

Dry Sump/Internal Reservoir

89 x 72 mm

168

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Specifications

Outlaw 450 MXR

Driving System Type

Shift Type

Primary Ratio

Gear Ratio - 1st

Gear Ratio - 2nd

Gear Ratio - 3rd

Gear Ratio - 4th

Gear Ratio - 5th

Gear Ratio - Reverse

Rear Two-Wheel Drive

5-Speed Manual Shift

Tire Size - Front

Tire Size - Rear

Tire Pressure - All

Front Brake

Rear Brake

Parking Brake

Headlight

Taillight

20 x 6R10

18 x 10R9

2.516

2.500

1.941

1.579

1.333

1.130

2.429

4 psi/27.6 KPa

Hydraulic Disc, Dual Bore

Hydraulic Disc

Hydraulic lock, front wheel

Dual Beam (55w/60w)

LED

Brakelight

LED

Outlaw 450 MXR Jetting Chart

AMBIENT TEMPERATURE

ALTITUDE

Meters (Feet)

0-1800 (0-6000)

Below 40° F (Below 5° C)

+40°F and above (+5°C and above)

Main Jet: 148

Needle Clip Position: #3

Main Jet: 138

Needle Clip Position: #3

1800-3700

(6000-12000)

Main Jet: 138

Needle Clip Position: #2

Main Jet: 125

Needle Clip Position: #2

169

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Specifications

Outlaw 525 S

Max. Weight Capacity

Dry Weight

Fuel Capacity

Overall Length

Overall Width

Overall Height

215 lbs./98 kg

370 lbs./168 kg

3.1 gal./11.8 l

71.5 in./182 cm

47.5 in./121 cm

45 in./114 cm

50.5 in./128 cm

5 in./13 cm

Pilot Jet

Main Jet

Clip Position

Jet Needle

Alternator Output

Compression Ratio

Starting System

Carburetor

Ignition System

Ignition Timing

#45

#138

OBDVS

200 w @ 3000 RPM

11:1

Electric

Keihin FCR-MX 39mm

CDI

25° +/- 3° @ 3500 RPM in

neutral

Wheelbase

Ground Clearance

Min. Turning Radius

Engine Oil Capacity

67 in./170 cm

1.7 qts./1.6 l

Coolant Capacity

Engine

Displacement

Bore x Stroke

2.25 qts./2.1 l

ES51KLE

510 cc

Spark Plug Type

Spark Plug Gap

Lubrication System

NGK DCPR8E

0.6 mm / .024 in.

Dry Sump/Internal Reservoir

95 x 72 mm

170

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Specifications

Outlaw 525 S

Driving System Type

Shift Type

Primary Ratio

Gear Ratio - 1st

Gear Ratio - 2nd

Gear Ratio - 3rd

Gear Ratio - 4th

Gear Ratio - 5th

Gear Ratio - Reverse

Rear Two-Wheel Drive

5-Speed Manual Shift

Tire Size - Front

Tire Size - Rear

Tire Pressure - All

Front Brake

Rear Brake

Parking Brake

Headlights

Taillight

21 x 7R10

20 x 11R9

2.516

2.500

1.941

1.579

1.333

1.130

2.429

4 psi/27.6 KPa

Hydraulic Disc, Dual Bore

Hydraulic Disc

Hydraulic lock, front wheel

Dual Beam (55w/60w)

LED

Brakelight

LED

Outlaw 525 S Jetting Chart

AMBIENT TEMPERATURE

ALTITUDE

Meters (Feet)

0-1800 (0-6000)

Below 40° F (Below 5° C)

+40°F and above (+5°C and above)

Main Jet: 148

Needle Clip Position: #4

Main Jet: 138

Needle Clip Position: #4

1800-3700

(6000-12000)

Main Jet: 138

Needle Clip Position: #3

Main Jet: 128

Needle Clip Position: #3

171

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Polaris Products

Part Number

Description

Engine Lubricant

2876244

2876245

PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt.)

PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal.)

Grease / Specialized Lubricants

2871312

2871322

2871423

2871460

2871329

Grease Gun Kit, Premium All Season (3 oz.)

Premium All Season Grease (3 oz. cartridge)

Premium All Season Grease (14 oz. cartridge)

Starter Drive Grease (2 oz.)

Dielectric Grease (Nyogelt)

Chain Lube, Aerosol (6.25 oz.)

Chain Lube, Aerosol (16 oz.)

Rear Shaft Grease (30 g)

2872073

2872348

1350046

172

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Polaris Products

Part Number

Description

Coolant

2871323

2871534

60/40 Coolant (gal.)

60/40 Coolant (qt.)

Additives / Miscellaneous

Carbon Clean Plus (12 oz.)

Fuel Stabilizer (16 oz.)

DOT4 Brake Fluid (12 oz.)

Hydraulic Clutch Oil (qt.)

2871326

2870652

2872189

2876335

173

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Troubleshooting

See your Polaris dealer if you're unable to identify solutions using the following charts.

Engine Turns Over, Fails to Start

Possible Cause

Solution

Out of fuel

Turn the fuel valve to reserve, refuel

Clean carburetor and/or drain fuel system and refuel

Turn the fuel valve on

Water is present in carburetor or fuel supply

Fuel valve is turned off

Engine is cold

Use choke to start a cold engine

Interrupted fuel supply

Turn the fuel valve off; remove the fuel hose at the

carburetor and place in a drain pan; turn the fuel valve

on.

•

If fuel leaks out, clean the carburetor.

•

If no fuel leaks out, clean the fuel valve.

Clogged fuel valve or filter

Old or non-recommended fuel

Fouled or defective spark plug(s)

Incorrect spark plug gap

Inspect and clean or replace

Replace with new fuel

Inspect and clean or replace plug(s)

Adjust gap to specification

174

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Troubleshooting

Engine Turns Over, Fails to Start

Possible Cause

Solution

No spark to spark plug

Inspect, clean and/or replace spark plugs

See your Polaris dealer

Overuse of choke/flooded engine

Engage starter 2 times for 5 seconds each, then restart.

If engine fails to start, inspect, clean and/or replace

spark plugs.

Low battery voltage

Recharge battery to 12.8 VDC

See your Polaris dealer

Ignition system or other mechanical failure

Throttle ETC switch not opening

Adjust throttle freeplay

The plug connection of the CDI-unit, pulse generator Clean the plug connection and treat with contact spray

or ignition coil has oxidized

175

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Troubleshooting

Engine Doesn’t Turn Over

Possible Cause

Solution

Fuseable link

See Polaris dealer for replacement

Recharge battery to 12.8 VDC

Check all connections and tighten

Low battery voltage

Loose battery connections

Loose solenoid connections

Engine Pings or Knocks

Possible Cause

Solution

Poor quality or low octane fuel

Incorrect ignition timing

Replace with recommended fuel

See your Polaris dealer

Incorrect spark plug gap or heat range

Set gap to specs or replace plugs

176

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Troubleshooting

Engine Backfires

Possible Cause

Solution

Weak, fouled or defective spark plug

Incorrect spark plug gap or heat range

Old or non-recommended fuel

Exhaust leak

Inspect, clean and/or replace spark plugs

Set gap to specs or replace plugs

Replace with new fuel

Inspect system for leaks; see your Polaris dealer

See your Polaris dealer

Incorrectly installed spark plug wire

Incorrect ignition timing

See your Polaris dealer

Mechanical failure

See your Polaris dealer

177

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Troubleshooting

Engine Runs Irregularly, Stalls or Misfires

Possible Cause

Solution

Fouled or defective spark plug

Worn or defective spark plug wire

Incorrect spark plug gap or heat range

Loose ignition connections

Defective ignition system

Inspect, clean and/or replace spark plug

See your Polaris dealer

Set gap to specs or replace plug

Check all connections and tighten

See your Polaris dealer

Water present in fuel

Replace with new fuel

Low battery voltage

Recharge battery to 12.8 VDC or replace

Inspect and replace

Kinked or plugged fuel vent line

Old or non-recommended fuel

Replace with recommended fuel

178

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Troubleshooting

Engine Runs Irregularly, Stalls or Misfires

Possible Cause

Solution

Inspect and clean or replace

Clogged air filter

Electronic throttle control malfunction

Incorrect idle adjustment

Clogged idle jet

See your Polaris dealer

Adjust idle speed or see your Polaris dealer

Disassemble carburetor and clean the jets

See your Polaris dealer

Other mechanical failure

179

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Troubleshooting

Engine Runs Irregularly, Stalls or Misfires

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

See your Polaris dealer

Old or non-recommended fuel

Clogged fuel valve screen

Incorrect jetting

See your Polaris dealer

Possible Rich Fuel Mixture Cause

Solution

Overuse of choke

Inspect, clean and/or replace spark plugs

Replace with recommended octane fuel

See your Polaris dealer

Fuel is very high octane

Incorrect jetting

Plugged, dirty or wet air filter

Clean pre-filter, replace main filter as needed

180

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Troubleshooting

Engine Fails to Reach High RPM

Possible Cause

Solution

Worn or dirty needle valve

Loose carburetor jets

Clean and/or replace needle valve

Tighten jets

Faulty ignition timing

See your Polaris dealer

Engine Uses Excessive Oil

Possible Cause

Solution

Bent engine ventilation hose

Excessive oil in system

Install a new hose

Check oil level, maintain at recommended level

Replace with a recommended oil

Use of non-recommended oil (too thin)

181

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Troubleshooting

Engine Stops or Loses Power

Possible Cause

Solution

Out of fuel

Turn the fuel valve to reserve, refuel

Clean fuel system and carburetor

Inspect and clean or replace

See your Polaris dealer

Interrupted fuel supply

Clogged, dirty or wet air filter

Electronic throttle control malfunction

Other mechanical failure

Overheated engine

See your Polaris dealer

Clean radiator screen and core if equipped

Clean engine exterior

Check oil level, maintain at recommended level

See your Polaris dealer

182

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Troubleshooting

Engine Stops or Loses Power

Possible Cause

Solution

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 plug

Worn or defective spark plug wire

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 12.8 VDC

Replace with recommended fuel

Old or non-recommended fuel

183

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Troubleshooting

Engine Overheats

Possible Cause

Solution

Debris lodged in radiator screen

Plugged radiator

Remove and clean the screen

Use a garden hose to flush any debris from the radia-

tor fins. NOTE: High pressure washers can deform the

radiator fins and reduce cooling efficiency.

Insufficient coolant

Check levels and fill as needed; check for leaks

Operate at a faster speed to increase air flow

Check oil level, maintain at recommended level

Bleed the cooling system

Insufficient air flow due to slow operation

Excessive oil in system

Cooling system has not been bled

Foam has formed in cooling system

Bent cooling hose

Drain and replace coolant with recommended coolant

Shorten or replace hose

Defective thermostat or thermoswitch

Blown fan fuse or defective fan

See your Polaris dealer

Replace fuse and check fan for proper operation or see

your Polaris dealer

184

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Troubleshooting

Engine Fails to Reach Full Power

Possible Cause

Solution

Interrupted fuel supply

Float leaks

Clean fuel system and carburetor

Replace the float

Clogged, dirty or wet air filter

Faulty exhaust system

Valve gap is too small

Faulty ignition timing

Inspect and clean or replace

Check system for damage; see your Polaris dealer

Adjust valve gap

See your Polaris dealer

185

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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 transferable to another consumer during the warranty period

through a Polaris dealer.

REGISTRATION

At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to Polaris

within ten days. Upon receipt of this registration, Polaris will record the registration for warranty. No verification

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

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 REGIS-

TERED 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.

186

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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 war-

ranty 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 war-

ranty does not cover physical damage to paint or finish, stress cracks, tearing or puncturing of upholstery mate-

rial, 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 replace-

ment of any defective materials, or components or products. THE REMEDIES SET FORTH IN THIS WAR-

RANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS

WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSE-

QUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS

OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHER-

WISE. 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.

187

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Warranty

WARRANTY COVERAGE AND EXCLUSIONS:

LIMITATIONS OF WARRANTIES AND REMEDIES

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.

188

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Warranty

HOW TO OBTAIN WARRANTY SERVICE

If your ATV requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris ATVs.

When requesting warranty service you must present your copy of the Warranty Registration form to the dealer.

(THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). Polaris

suggests that you use your original selling dealer; however, you may use any Polaris Servicing Dealer to perform

warranty service.

Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance

they will contact the appropriate personnel at Polaris.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

If any of the above terms are void because of state or federal law, all other warranty terms will remain in effect.

Engine Oil

1. Mixing oil brands or using non-recommended oil may cause engine damage. We recommend the use of Polaris

engine oil.

2. Damage resulting from the use of non-recommended lubricants may not be covered by warranty.

Spark Arrestor

Polaris warrants that the spark arrestor in this vehicle will meet the efficiency requirements of 43 CFR 8340.1(c)

for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance

with Polaris recommendations.

189

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Warranty

EXPORTED VEHICLES

EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BUL-

LETIN 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 war-

ranty or service bulletin coverage if you have any questions.

This policy does not apply to vehicles registered to government officials or military personnel on assignment out-

side the country of the selling dealer's authorized location.

This policy does not apply to Safety Recalls.

190

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Warranty

EXPORTED VEHICLES

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 sell-

ing dealer's authorized location as proof of residence. Upon residence verification, the servicing dealer will be

authorized to perform the warranty repair.

If You Move:

If you move to another country, be sure to contact Polaris Customer Assistance and the customs department of the

destination country before you move. Vehicles importation rules vary considerably from country to country. You

may be required to present documentation of your move to Polaris Industries in order to continue your warranty

coverage. You may also be required to obtain documentation from Polaris Industries in order to register your

vehicle in your new country.

191

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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 purchased, and you have not followed the proce-

dure set out above, your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind.

(Vehicles registered to Government officials or military personnel on assignment outside of the country where the

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

For questions call Polaris Customer Assistance:

United States: 1-888-704-5290

Canada: 1-204-925-7100

192

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Warranty

U.S.A. EPA Emissions Limited Warranty

This All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited warranty is in addition to

the Polaris standard limited warranty for this vehicle.

Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at the time of initial sale with

the requirements of 40 CFR 1051 and, (2) free from defects in materials and workmanship that may keep it from

meeting these requirements.

The emissions warranty period for this vehicle begins on the date the vehicle is delivered to the original retail pur-

chaser and ends 30 months (2.5 years) after that date, after 5000 km (3100 miles), or after 500 hours of operation,

whichever comes first.

This emission-related warranty covers components whose failure would increase an engine's emissions, including

electronic controls, fuel injection, exhaust-gas recirculation, aftertreatment, or any other system utilized in this

vehicle to control emissions. Replacing or repairing other components not covered by this emissions warranty or

the standard warranty is the responsibility of the owner; including the parts, labor and other costs associated with

recommended maintenance.

193

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Warranty

U.S.A. EPA Emissions Limited Warranty

The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of Polaris, repair or

replacement of any defective materials, components or products. THE REMEDIES SET FORTH IN THIS LIM-

ITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS

WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSE-

QUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION,WHETHER ARISING OUT OF EXPRESS

OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR OTHER-

WISE.

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF

MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO

THE WARRANTY PERIOD DESCRIBED HEREIN. POLARIS 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 if it is inconsistent with the controlling state law.

This limited warranty excludes failures not caused by a defect in material or workmanship. This limited warranty

does not cover damage due to accidents, abuse or improper handling, maintenance or use. This limited warranty

also does not cover any engine that has been structurally altered, or any engine that has been used in racing com-

petition. This limited warranty also does not cover physical damage, corrosion or defects caused by fire, explo-

sions or other similar causes beyond the control of Polaris.

If you have any questions regarding your warranty rights and responsibilities, you should contact the Polaris War-

ranty Department at 1-888-704-5290.

194

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Maintenance Log

Present this section of your manual to your dealer each time your vehicle is serviced. This will provide you and

future owners with an accurate log of maintenance and services performed.

DATE

SERVICE

INTERVAL

(HOURS)

TECHNICIAN

SERVICE PERFORMED / COMMENTS

3 Hours

(Break-in)

195

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Maintenance Log

DATE

SERVICE

INTERVAL

(HOURS)

TECHNICIAN

SERVICE PERFORMED / COMMENTS

196

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Maintenance Log

DATE

SERVICE

INTERVAL

(HOURS)

TECHNICIAN

SERVICE PERFORMED / COMMENTS

197

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Maintenance Log

DATE

SERVICE

INTERVAL

(HOURS)

TECHNICIAN

SERVICE PERFORMED / COMMENTS

198

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Index

Age Restrictions . . . . . . . . . . . . . . 15

Air Filter Systems . . . . . . . . . . . . 112

Cab Removal, Front . . . . . . . . . . . 120

Cab Removal, Rear . . . . . . . . . . . 121

Camber and Caster. . . . . . . . . . . . 151

Carburetor . . . . . . . . . . . . . . 113-114

Carburetor Draining. . . . . . . . . . . 114

Carburetor Jetting. . . . . . . . . . . . . 115

Chain Tension Adjustment. . 148-149

Chain Tension Inspection. . . 146-147

Cleaning . . . . . . . . . . . . . . . . 158-160

Clothing . . . . . . . . . . . . . . . . . . . . . 14

Clutch Fluid . . . . . . . . . . . . . . . . . . 43

Clutch Lever. . . . . . . . . . . . . . . . . . 42

Clutch System Bleeding. . . . 138-139

Compression Damping. . . . . . . . . 153

Compression Damping, Rear . . . . 157

Consumer Product Safety. . . . . . . . 11

Coolant Level, Radiator. . . . . . . . 110

Coolant Level, Recovery Bottle. . 109

Cooling System . . . . . . . . . . 108-111

Cooling System Bleeding. . . . . . . 111

Deceleration . . . . . . . . . . . . . . . . . 55

Driving Downhill . . . . . . . . . . . . . 78

Driving in Reverse . . . . . . . . . . 82-83

Driving on a Sidehill . . . . . . . . . . . 74

Driving on Slippery Surfaces . . 70-71

Driving Over Obstacles. . . . . . . . . 84

Driving Procedures . . . . . . . . . . . . 68

Driving Through Water. . . . . . . 80-81

Driving Uphill . . . . . . . . . . . . . . 72-73

Battery

Charging. . . . . . . . . . . . 132-134

Installation . . . . . . . . . . . . . 131

Maintenance. . . . . . . . . . . . 129

Removal. . . . . . . . . . . . . . . 130

Storage . . . . . . . . . . . . 130, 162

Bleeding the Cooling System . . . 111

Boots . . . . . . . . . . . . . . . . . . . . . . . 14

Brake Fluid . . . . . . . . . . . . . . . . 48-49

Brake Maintenance . . . . . . . . 142-143

Brakes

Foot Brake . . . . . . . . . . . . . . 46

Hand Brake . . . . . . . . . . . . . 47

Parking Brake . . . . . . . . . 50-51

Break-in Period. . . . . . . . . . . . . 58-59

Electronic Throttle Control . . . . . . 45

Emission Control Systems . . . . 85-86

Engine Idle Speed . . . . . . . . . . . . 113

Equipment Modifications . . . . . . . 12

Etiquette, Trail Riding. . . . . . . . . . 65

Exhaust, Exposure to. . . . . . . . . . . 17

Eye Protection . . . . . . . . . . . . . . . . 14

199

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Index

Fluid

Idle Speed . . . . . . . . . . . . . . . . . . 113

Indicator Lights . . . . . . . . . . . . . . . 40

Instruction, Operating . . . . . . . . . . 16

Main Key Switch . . . . . . . . . . . . . . 39

Maintenance Chart . . . . . . . . . . 87-97

Making Turns . . . . . . . . . . . . . . . . . 69

Manual Shift . . . . . . . . . . . . . . . 52-55

Master Cylinder . . . . . . . . . . . . 48-49

Modifications . . . . . . . . . . . . . . . . . 12

Brake . . . . . . . . . . . . . . . . 48-49

Clutch . . . . . . . . . . . . . . . . . . 43

Foot Brake . . . . . . . . . . . . . . . . . . . 46

Foot Brake Fluid Level . . . . . . . . . 49

Fuel Filter . . . . . . . . . . . . . . . . . . . . 56

Fuel Safety . . . . . . . . . . . . . . . . . . . 17

Fuel Stabilizer . . . . . . . . . . . . . . . 164

Fuel Tank . . . . . . . . . . . . . . . . . . . . 56

Fuel Valve . . . . . . . . . . . . . . . . . . . 57

Jetting . . . . . . . . . . . . . . . . . . . . . 115

Jetting Specifications

Outlaw 450 MXR . . . . . . . . 169

Outlaw 525 S . . . . . . . . . . . 171

Oil Change, Engine. . . . . . . . 100-107

Oil Level, Engine . . . . . . . . . . . . . . 99

Oil Recommendations . . . . . . . . . . 98

Operator Restrictions . . . . . . . . . . . 15

Key Switch . . . . . . . . . . . . . . . . . . 39

K-Turn. . . . . . . . . . . . . . . . . . . . . . 75

Gasoline Handling . . . . . . . . . . . . . 17

Gloves. . . . . . . . . . . . . . . . . . . . . . . 14

Parking Brake . . . . . . . . . . . . . . 50-51

Parking on a Hill or Incline . . . . . . 79

Passenger Warning . . . . . . . . . . . . . 37

Periodic Maintenance Chart . . . 87-97

Polaris Products . . . . . . . . . . . . . . 172

Polishing . . . . . . . . . . . . . . . . . . . . 161

Pre-Ride Inspection . . . . . . . . . 60-61

Lights . . . . . . . . . . . . 40-41, 116-119

Headlight Adjustment. 116-117

Headlight Assembly . . . . . . 119

Headlights. . . . . . . . . . . . . . . 41

Indicator Lights . . . . . . . . . . 40

Hand Brake. . . . . . . . . . . . . . . . . . . 47

Hand Brake Fluid Level . . . . . . . . . 49

Handlebar Adjustment . . . . . . . . . 150

Headlight Adjustment . . . . . 116-117

Headlight Assembly . . . . . . . . . . . 119

Headlights. . . . . . . . . . . . . . . . . . . . 41

Helmet . . . . . . . . . . . . . . . . . . . . . . 13

200

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Index

Rebound Damping, Rear. . . . . . . 156

Restrictions, Age. . . . . . . . . . . . . . 15

Reverse Lock-Out Switch. . . . . . . 54

Riding Area. . . . . . . . . . . . . . . . . . 64

Riding Gear. . . . . . . . . . . . . . . . 13-14

Safety Warnings . . . . . . . . . . . 15-33

Damaged ATV . . . . . . . . . . . 32

Deep Water . . . . . . . . . . . . . . 30

Descending Hills Improperly 24

Excessive Speed . . . . . . . . . . 21

Exposure to Exhaust . . . . . . . 17

Failure to Inspect . . . . . . . . . 18

Frozen Bodies of Water . . . . 32

Handling Gasoline. . . . . . . . . 17

Hot Exhaust Systems . . . . . . 33

Improper Cargo Loading. . . . 31

Improper Hill Climbing . . . . 23

Improper Tire Maintenance . 28

Improper Modifications . . . . 29

Instruction . . . . . . . . . . . . . . . 16

Jumps and Stunts. . . . . . . . . . 22

Obstacles . . . . . . . . . . . . . . . . 29

Pavement. . . . . . . . . . . . . . . . 20

Physical Control of the ATV 21

Physical Skills. . . . . . . . . . . . 32

Safety Warnings . . . . . . . . . . . 15-33

Poor Visibility . . . . . . . . . . . 31

Protective Apparel . . . . . . . . 18

Public Roads. . . . . . . . . . . . . 20

Reverse. . . . . . . . . . . . . . . . . 28

Skidding or Sliding . . . . . . . 29

Slippery Terrain . . . . . . . . . . 27

Stalling Climbing a Hill . . . . 26

Steep Hills . . . . . . . . . . . . . . 23

Turning Improperly . . . . . . . 22

Unauthorized Use. . . . . . . . . 33

Unfamiliar Terrain . . . . . . . . 28

Using Alcohol or Drugs . . . . 19

Safety Words and Symbols . . . . . . . 6

Severe Use. . . . . . . . . . . . . . . . . . . 88

Shift Pedal . . . . . . . . . . . . . . . . . . . 52

Shifting Gears . . . . . . . . . . . . . . . . 53

Side Panel Removal . . . . . . . . . . 120

Sidehilling . . . . . . . . . . . . . . . . . . . 74

Signal words . . . . . . . . . . . . . . . . . . 6

Safe Operation Practices. . . . . . 62-63

Safety Labels and Locations . 34-37

Age 16 Warning. . . . . . . . . . 36

Discretionary Warning. . . . . 36

General Warning . . . . . . . . . 35

No Passenger Warning. . . . . 37

Sport ATV Warning. . . . . . . 36

Tire Pressure/Load Warning 37

Safety Training . . . . . . . . . . . . . 10-11

Safety Warnings . . . . . . . . . . . 15-33

Age Restrictions. . . . . . . . . . 15

Carrying a Passenger . . . . . . 19

Crossing Hillsides . . . . . . . . 25

201

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Index

Spark Arrestor Clean-Out. . . 124-125

Spark Plugs. . . . . . . . . . . . . . 122-123

Spring Preload . . . . . . . . . . . . . . . 153

Spring Preload, Front . . . . . . . . . . 154

Spring Preload, Rear . . . . . . . . . . 155

Starting the Engine. . . . . . . . . . 66, 67

Steering Inspection. . . . . . . . . . . . 151

Storage . . . . . . . . . . . . . . . . . 162-165

Suspension

Throttle Cable Freeplay. . . . . . . . 141

Throttle Lever . . . . . . . . . . . . . 44-45

Throttle Lever Freeplay. . . . . . . . 140

Tires

Vehicle Identification Numbers . . 8-9

Vehicle Immersion . . . . . . . . 126-128

Installation . . . . . . . . . . . . . 137

Removal . . . . . . . . . . . . . . . 136

Tread Depth . . . . . . . . . . . . 135

Wheel Hub Tightening . . . . 136

Toe Alignment. . . . . . . . . . . 144-145

Trail Etiquette . . . . . . . . . . . . . . . . 65

Transporting the ATV . . . . . 166-167

Tread Lightly. . . . . . . . . . . . . . . . . 64

Turning Around on a Hill . . . . 75-77

Warranty, Emissions. . . . . . . 193-194

Washing the Vehicle. . . . . . . 158-160

Wheel Hub Tightening . . . . . . . . . 136

Wheel Installation. . . . . . . . . . . . . 137

Wheel Removal . . . . . . . . . . . . . . 136

Front . . . . . . . . . . . . . . 153-154

Rear . . . . . . . . . . . . . . . 155-157

Suspension Settings . . . . . . . . . . . 152

Switches

Engine Stop Switch . . . . . . . . 39

Main Key Switch. . . . . . . . . . 39

Reverse Lock-Out Switch . . . 54

Start Button . . . . . . . . . . . . . . 39

202

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