Polaris Offroad Vehicle 700 EFI X2 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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WELCOME

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

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

utility and recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER utility vehicles

• Victory motorcycles

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

ational vehicles manufactured in the world today. Many years of experi-

ence have gone into the engineering, design, and development of your

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

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

instructions and recommendations in this owner’s manual. Your manual

contains instructions for minor maintenance, but information about

major repairs is outlined in the Polaris Service Manual and should be

performed only by a Factory Certified Master Service Dealer (MSD)

Technician.

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

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

vice needs during, and after, the warranty period.

We also take great pride in our complete line of apparel, parts and acces-

sories, available through our online store at www.purepolaris.com. Have

your accessories and clothing delivered right to your door!

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

tries Inc.

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

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

ancies may result between the actual vehicle and the information presented in this publi-

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

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

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

expressly prohibited.

Printed in U.S.A.

2008 Sportsman 500/700/800 X2 Owner’s Manual

P/N 9921356

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TABLE OF CONTENTS

Know Your Vehicle . . . . . . . . . . . . . . . . . . . . . . . 5

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Emission Control Systems . . . . . . . . . . . . . . . 84

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 139

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 143

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 144

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 156

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

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KNOW YOUR VEHICLE

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

safety, the safety of others (including your passenger), and the protec-

tion of our environment. Read and understand your owner's manual,

which includes valuable information about all aspects of your vehicle,

including safe operating procedures.

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.

500

VIN

Engine Serial Number

####

Key Number

700/800

Vehicle Model Number: ___________________________________________________

Frame VIN: _____________________________________________________________

Engine Serial Number: ____________________________________________________

Key Number: ___________________________________________________________

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SAFETY

Safety Decals and Locations

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

and follow the instructions of the decals on the ATV carefully. If any of

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

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

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

to purchase a replacement. Replacement safety decals are provided by

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

Discretionary Warning

WARNING

Age 16 Warning

• Never operate this ATV on HILLS

steeper than 15 degrees

15°. To

prevent flip-over on hilly terrain, when

going up or down, use throttle and

brakes gradually.

• Never operate this vehicle in

mode on irregular terrain, including

hills and obstacles.

• REVERSE operation can be

dangerous even at low speeds.

Steering becomes difficult. To prevent

flipover, avoid sudden braking or

sharp turns.

Discretionary Warning

• Use OVERRIDE for reverse speed limiter with caution. To prevent loss of

control, never activate override button with open throttle.

• When this vehicle is not in operation, or unattended, place shift in the park

position.

7175108

Age 16 Warning

WARNING

Operating this ATV if you are under the age of 16 increases your chance of

severe injury or death.

NEVER operate this ATV if you are under age 16.

7172588

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SAFETY

Safety Decals and Locations

General Warning

WARNING

Improper ATV use can result in SEVERE

INJURY or DEATH

ALWAYS USE AN APPROVED HELMET

AND PROTECTIVE GEAR FOR

OPERATOR AND PASSENGER

NEVER USE ON PUBLIC ROADS

NEVER CARRY MORE THAN ONE

PASSENGER

NEVER USE WITH DRUGS OR

ALCOHOL

General

Warning

NEVER operate:

• without proper training or instruction

• at speeds too fast for your skills, your passenger’s skills, or the conditions

• on public roads - a collision can occur with another vehicle

• with more than one passenger - passengers affect balance and steering and

increase risk of losing control

• with a passenger under the age of 12

THE OPERATOR MUST ALWAYS:

• use proper riding techniques to avoid vehicle overturns on hills and rough

terrain and in turns

• avoid paved surfaces - pavement may seriously affect handling and control

• reduce speed and use extra caution at all times when carrying a passenger -

have passenger dismount when conditions require

• make sure passenger reads and understands this label and passenger safety

label

LOCATE AND READ OWNER’S MANUAL.

FOLLOW ALL INSTRUCTIONS AND WARNINGS.

IF OWNER’S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A

REPLACEMENT.

7173889

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SAFETY

Safety Decals and Locations

Passenger Safety Warning

WARNING

PASSENGER SAFETY

To reduce the risk of SEVERE INJURY or

DEATH

NEVER CARRY A PASSENGER

UNDER AGE 12

NEVER CARRY MORE THAN ONE

PASSENGER

NEVER RIDE AFTER USING DRUGS

OR ALCOHOL

NEVER carry a passenger too small to

firmly plant feet on footrests and securely

grasp hand holds.

THE PASSENGER MUST ALWAYS:

• use an approved helmet and protective

gear

Passenger Safety

Warning

• securely grasp hand holds and plant feet firmly on footrests

• tell operator to slow down or stop if uncomfortable - get off and walk if

conditions require

7174028

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SAFETY

Safety Decals and Locations

Tire Pressure/Load Warning

WARNING

IMPROPER TIRE PRESSURE OR

OVERLOADING can cause loss of

control resulting in SEVERE INJURY

OR DEATH.

Tire Pressure/Load

Warning

TIRE PRESSURE IN PSI (KPa):

FRONT 5 (34.5) REAR 5 (34.5)

MAXIMUM WEIGHT CAPACITY

705 LBS. (320 kg)

INCLUDES WEIGHT OF

OPERATOR, PASSENGER,

CARGO AND ACCESSORIES.

Reduce speed and allow greater

distance for braking when carrying

cargo. Overloading or carrying tall,

off-center, or unsecured loads will

increase your risk of losing control.

Loads should be centered, carried

as low as possible in box, and firmly

secured to the box. For stability on

rough or hilly terrain, reduce speed

and cargo. Do not block headlight.

Be careful if load extends over the

side of the rack or box.

Read Owner's Manual for more detailed loading information.

7174885

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SAFETY

Safety Decals and Locations

Box

Warning

Rack

Warning

Clutch Cover

Warning

Rack Warning, Front

WARNING

DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may

result causing severe injury or death. Tow only from tow hooks or hitch.

Maximum combined Front Rack and Container Load: 90 lbs. (41 kg)

7174201

Clutch Cover Warning

WARNING

NO STEP

• Moving parts hazard under belt-clutch guard. To prevent serious injury, do not

operate vehicle with guard removed.

• Do not modify engine or clutch. Doing so can cause part failure, possible

imbalance, and excessive engine RPM, which can result in serious injury or

death.

7172563

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SAFETY

Safety Decals and Locations

Reverse Override Warning

WARNING

Pushing reverse override button may cause sudden increases in power and

traction if too much throttle is applied. Loss of control or forward flipover may

result, especially in 4X4 (AWD). See Owner's Manual.

7175106

Box Warning

WARNING

Remove flammable material

containers from box before filling.

WARNING

Passengers can be thrown off. This can cause serious

injury or death. Never carry passengers in cargo box.

Maximum Box Load - 400 lbs. (181 kg)

7173890

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SAFETY

Safe Riding Gear

Always wear appropriate clothing when riding an ATV. Wear protective

clothing for comfort and to reduce the chance of injury.

Helmet

Eye Protection

Long

Sleeves

Gloves

Long Pants

Boots

Helmet

Wearing a helmet can prevent a severe head injury. Whenever riding a

Polaris vehicle, always wear a helmet that meets or exceeds established

safety standards.

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

Transportation (DOT) label.

Approved helmets in Europe, Asia and Oceania

bear the ECE 22.05 label. The ECE mark consists

of a circle surrounding the letter E, followed by the

distinguishing number of the country which has

granted approval. The approval number and serial

number will also be displayed on the label.

051039

0006.31

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SAFETY

Safe Riding Gear

Eye Protection

Do not depend on eyeglasses or sunglasses for eye protection. When-

ever riding a Polaris vehicle, always wear shatterproof goggles or use a

shatterproof helmet face shield. Polaris recommends wearing approved

Personal Protective Equipment (PPE) bearing markings such as VESC

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

Gloves

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

protection.

Boots

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

Clothing

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

Riding pants with kneepads and a jersey with shoulder pads provide the

best protection.

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SAFETY

Rider Safety

WARNING

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

injury or death.

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

handles differently than other vehicles, such as motorcycles and cars. A

collision or rollover can occur quickly, even during routine maneuvers like

turning, or driving on hills or over obstacles, if you fail to take proper

precautions.

Read and understand your owner's manual and all warnings before operating

a Polaris ATV.

Age Restrictions

This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited

for anyone under 16 years of age. Never allow anyone under 12 years of

age to ride as a passenger on this 2-up ATV.

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SAFETY

Rider 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 eligible family members who will be riding

the ATV to take the ATV RiderCourse^sm. You were also provided with

printed materials that explain safe operating procedures. You should

review this information on a regular basis.

If you purchased a used Polaris ATV, 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.

A Polaris ATV is an off-road vehicle. Familiarize yourself with all laws

and regulations concerning the operation of this vehicle in your area.

We strongly advise you to strictly follow the recommended maintenance

program outlined in your owner's manual. This preventive maintenance

program is designed to ensure that all critical components on your

vehicle are thoroughly inspected at specific intervals.

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SAFETY

Rider Safety

The following signal words and symbols appear throughout this manual

and on your vehicle. Your safety is involved when these words and sym-

bols are used. Become familiar with their meanings before reading the

manual.

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

potential for injury.

WARNING

The safety alert warning indicates a potential hazard that may result in serious

injury or death.

CAUTION

The safety alert caution indicates a potential hazard that may result in minor

injury or damage to the vehicle.

CAUTION

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

NOTE

A note will alert you to important information or instructions.

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SAFETY

Rider Safety

WARNING

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

procedures, which are outlined in further detail within your owner's manual.

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

procedures described.

• 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.

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

• Never allow anyone under 12 years of age to ride as a passenger on

this 2-up ATV. Make sure any passenger is tall enough to comfortably

and safely reach the handgrips and footrests.

• Never secure a passenger to the vehicle or to the operator with a belt,

rope or similar device.

• Never carry more than one passenger on this 2-up ATV.

• Always make sure the passenger seat lock-out is functioning properly

before carrying a passenger.

• 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.

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

rests of the ATV during operation. A passenger should always be

seated in the passenger seat with both feet on the footrests and both

hands on the passenger grab handles at all times. The passenger

should never hold on to the operator.

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

walks, driveways, parking lots, and streets.

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

dirt or gravel road.

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SAFETY

Rider Safety

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

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

boots, a long-sleeved shirt or jacket, and long pants. A passenger's

helmet should have a rigid chin guard.

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

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

your skills, your passenger's skills, and operating conditions.

• Never attempt jumps or other stunts.

• Always inspect your ATV before each use to make sure it's in safe

operating condition. Always follow the inspection and maintenance

procedures and schedules outlined in your owner's manual.

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

miliar terrain. Be alert to changing terrain conditions.

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

• Always follow proper turning procedures as described in this manual.

Practice turning at low speeds before attempting to turn at faster

speeds. Do not turn at excessive speeds.

• Always have the ATV inspected by an authorized Polaris dealer if it's

been involved in an accident.

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

Practice on smaller hills before attempting larger hills.

• Never operate with the differential unlocked ( ) while operating on

a hill or other irregular terrain. See pages 39 and 49.

• Always follow proper procedures for climbing hills. Check the terrain

carefully before ascending a hill. Never climb hills with excessively

slippery or loose surfaces. Shift your weight uphill. Never open the

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

of a hill at high speed. Always move the 4X4 switch to ADC 4X4

before ascending or descending a hill.

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SAFETY

Rider Safety

• Always follow proper procedures for going downhill and for braking

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

your weight uphill. Never go down a hill at high speed. Avoid going

down a hill at an angle, which would cause the vehicle to lean sharply

to one side. Drive straight downhill.

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

not cross a hillside with a passenger on board. Avoid hills with exces-

sively slippery or loose surfaces. Shift your weight uphill. Never

attempt to turn the ATV around on any hill until you've mastered (on

level ground) the turning technique outlined in this manual. Avoid

crossing the side of a steep hill when possible.

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

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

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

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

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

the ATV around and remount following the procedure described in

this manual.

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

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

Always follow proper procedures when operating over obstacles as

described in this manual.

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

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

ding or sliding out of control.

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

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

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

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

changes.

• Wet brakes may have reduced stopping ability. Test the brakes after

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

friction to dry out the pads.

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SAFETY

Rider Safety

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

ing in reverse. Be aware that a passenger can obstruct your view.

When it's safe to proceed in reverse, move slowly and avoid turning at

sharp angles.

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

always maintain proper tire pressure.

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

sories.

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

properly distributed and securely attached. Reduce speed and follow

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

greater distance for braking.

FOR MORE INFORMATION ABOUT ATV SAFETY, call the

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

Rider 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 substantial safety hazard and increase the risk of bodily injury.

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

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

vehicle, that increase its speed or power.

NOTE: The addition of certain accessories, including (but not limited to) mow-

ers, 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

Rider Safety

WARNING

POTENTIAL HAZARD

Operating this ATV without proper instruction.

WHAT CAN HAPPEN

The risk of an accident is greatly increased if the

operator does not know how to operate the ATV

properly in different situations and on different

types of terrain.

HOW TO AVOID THE HAZARD

Beginning and inexperienced operators should

complete the 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.

WARNING

POTENTIAL HAZARD

Failure to follow the age recommendations for this ATV.

WHAT CAN HAPPEN

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

recommendation operates this ATV or rides as a passenger.

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 or ride on this ATV safely and could be susceptible to accident or

injury.

HOW TO AVOID THE HAZARD

No one under the age of 16 should operate a Polaris ATV. Never allow

anyone under 12 years of age to ride as a passenger on this 2-up ATV.

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SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD

Operating with more than one passenger.

WHAT CAN HAPPEN

Passengers affect balance and steering and

increase the risk of losing control, which can

result in severe injury or death.

HOW TO AVOID THE HAZARD

Never operate the 2-up ATV with more than

one passenger.

WARNING

POTENTIAL HAZARD

Carrying a passenger in the cargo box.

WHAT CAN HAPPEN

A passenger riding in the cargo box could fall

from the vehicle unexpectedly or may contact

moving components, both of which can result

in severe injury or death.

HOW TO AVOID THE HAZARD

Never allow a passenger to ride in the cargo

box.

WARNING

POTENTIAL HAZARD

Operating an ATV on paved surfaces, including

sidewalks, paths, parking lots, and driveways.

WHAT CAN HAPPEN

ATV tires are designed for off-road use.

Operating on paved surfaces may adversely

affect the handling of the ATV and could result in

loss of control, accident, and/or injury.

HOW TO AVOID THE HAZARD

Avoid operating the ATV on pavement. If it's

unavoidable, travel slowly and avoid sudden turns or stops.

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SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD

Operating this ATV on public streets,

roads or highways.

WHAT CAN HAPPEN

The ATV could collide with another

vehicle.

HOW TO AVOID THE HAZARD

Never operate the ATV on any public

street, road or highway, including dirt and

gravel roads. In many states it's illegal to

operate ATVs on public streets, roads

and highways.

WARNING

POTENTIAL HAZARD

Riding an ATV without wearing an

approved helmet, eye protection and

protective clothing.

WHAT CAN HAPPEN

Riding an ATV without an approved

helmet increases the risk of a severe head

injury or death in the event of an accident.

Riding without eye protection could result

in an accident and could increase the

chance of a severe injury in the event of

an accident.

HOW TO AVOID THE HAZARD

Always be sure operator and passenger wear an approved helmet that fits

properly. A passenger's helmet should have a rigid chin guard.

Always be sure operator and passenger wear eye protection (goggles or face

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

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SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD

Operating the ATV after consuming alcohol or

drugs.

WHAT CAN HAPPEN

Consumption of alcohol and/or drugs could

seriously affect operator judgment. Reaction

time may be slower and operator balance and

perception could be affected.

Consuming alcohol and/or drugs before or while

operating an ATV could result in an accident

causing severe injury or death.

HOW TO AVOID THE HAZARD

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

WARNING

POTENTIAL HAZARD

Operating the ATV at excessive

speeds.

WHAT CAN HAPPEN

Excessive speed increases the

operator's chance of losing

control of the ATV, which can

result in an accident causing

severe injury or death.

HOW TO AVOID THE HAZARD

Never operate at excessive

speeds. Travel at speeds

appropriate for your skills, your

passenger's skills, and operating conditions.

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SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD

Attempting jumps and other stunts.

WHAT CAN HAPPEN

Attempting stunts increases the chance of

an accident, including an overturn.

HOW TO AVOID THE HAZARD

Never attempt jumps or other stunts.

Avoid exhibition driving.

WARNING

POTENTIAL HAZARD

Failure to inspect the ATV before operating.

Failure to properly maintain the ATV.

WHAT CAN HAPPEN

Poor maintenance increases the possibility of

an accident or equipment damage.

HOW TO AVOID THE HAZARD

Always inspect your ATV before each use to

make sure it's in safe operating condition.

Always follow the inspection and maintenance

procedures and schedules described in the owner's manual.

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SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD

Removing hands from the handlebars or

feet from the footrests during operation.

WHAT CAN HAPPEN

Removing even one hand or foot can

reduce ability to control the vehicle or

could cause loss of balance and ejection

from the ATV.

If a person's feet are not firmly planted on

the footrests, they could come into

contact with the wheels or other moving

parts and lead to accident or injury.

HOW TO AVOID THE HAZARD

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

the ATV during operation. A passenger should always be seated in the

passenger seat with both feet on the footrests and both hands on the

passenger grab handles at all times. The passenger should never hold on to

the operator.

WARNING

POTENTIAL HAZARD

Failure to use extra caution when

operating the ATV on unfamiliar terrain.

WHAT CAN HAPPEN

Unfamiliar terrain may contain hidden

rocks, bumps, or holes that could

cause loss of control or overturn.

HOW TO AVOID THE HAZARD

Travel slowly and use extra caution

when operating on unfamiliar terrain.

Always be alert to changing terrain

conditions.

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SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD

Failure to use extra caution when

operating on excessively rough,

slippery or loose terrain.

WHAT CAN HAPPEN

Operating on excessively rough,

slippery or loose terrain could cause

loss of traction or loss of control,

which could result in an accident or

overturn.

HOW TO AVOID THE HAZARD

Do not operate on excessively rough, slippery or loose terrain until you've

learned and practiced the skills necessary to control the ATV on such terrain.

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

WARNING

POTENTIAL HAZARD

Turning improperly.

WHAT CAN HAPPEN

Improper turns could cause loss of control and

lead to a collision or overturn.

HOW TO AVOID THE HAZARD

Always follow proper procedures for turning as

described in the owner's manual.

Practice turning at slow speeds before

attempting to turn at faster speeds.

Never turn at excessive speed.

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SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD

Operating on excessively steep hills.

WHAT CAN HAPPEN

The vehicle may overturn.

HOW TO AVOID THE HAZARD

Never operate on hills too steep for

the ATV or for your abilities. Never

operate the ATV on hills steeper than

15 degrees.

>15°

WARNING

POTENTIAL HAZARD

Climbing hills improperly.

WHAT CAN HAPPEN

Improper hill climbing could cause loss

of control or overturn.

HOW TO AVOID THE HAZARD

Always follow proper procedures for

climbing hills as described in the

owner's manual. See page 73.

Always move the 4X4 switch to ADC

4X4 before ascending or descending a

hill. See page 49.

Always check the terrain carefully before ascending any hill.

Never climb hills with excessively slippery or loose surfaces.

Shift body weight uphill. A passenger should also shift body weight uphill.

Never open the throttle suddenly while traveling uphill. The ATV could flip

over backwards.

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

another vehicle or person could be on the other side of the hill.

^{Never operate with the differential unlocked}( ) while operating on a hill or

other irregular terrain. Always move the 4X4 switch to ADC 4X4 before

ascending or descending a hill. See pages 39 and 49.

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SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD

Traveling downhill improperly.

WHAT CAN HAPPEN

Improperly descending a hill

could cause loss of control or

overturn.

HOW TO AVOID THE

HAZARD

Always follow proper

procedures for traveling down

hills as described in the owner's

manual. See page 75.

^{Never operate with the differential unlocked}( ) while operating on a hill or

other irregular terrain. Always move the 4X4 switch to ADC 4X4 before

ascending or descending a hill. See pages 39 and 49.

Always check the terrain carefully before descending a hill.

Always descend a hill with the transmission in forward gear. Do not descend

a hill with the transmission in neutral.

Shift body weight uphill. A passenger should also shift body weight uphill.

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

Rider Safety

WARNING

POTENTIAL HAZARD

Improperly crossing hills and turning on

hills.

WHAT CAN HAPPEN

Improperly crossing or turning on hills

could cause loss of control or overturn.

HOW TO AVOID THE HAZARD

Never attempt to turn the ATV around on

any hill until you've mastered the turning

technique (on level ground) as described in

the owner's manual. See page 76. Use

extra caution when turning on any hill.

Do not cross a hillside with a passenger on board.

Avoid crossing the side of a steep hill.

When crossing the side of a hill:

Always follow proper procedures as described in the owner's manual.

Avoid hills with excessively slippery or loose surfaces.

Shift your weight to the uphill side of the ATV.

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SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD

Stalling, rolling backwards or

improperly dismounting while

climbing a hill.

WHAT CAN HAPPEN

The vehicle could overturn.

HOW TO AVOID THE HAZARD

Maintain steady speed when

climbing a hill.

Always move the 4X4 switch to ADC

4X4 before ascending or descending

a hill. See page 49.

If all forward speed is lost:

Lean forward to keep body weight uphill. A passenger should also lean uphill.

Apply the single lever brakes.

Lock the parking brake when fully stopped.

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

pointing straight uphill. Have a passenger dismount first, then the operator

may dismount.

Turn the ATV around and remount, following the procedure described in the

owner's manual. See page 76.

If the ATV begins rolling backwards:

Keep operator and passenger body weight uphill.

Never apply engine power.

Never apply the rear brake while rolling backwards.

Apply the single-lever brake gradually.

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

brake.

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

pointing straight uphill. Have a passenger dismount first, then the operator

may dismount.

Turn the ATV around and remount, following the procedure described in the

owner's manual. See page 76.

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SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD

Improperly operating over obstacles.

WHAT CAN HAPPEN

Operating over obstacles could cause

loss of control or overturn.

HOW TO AVOID THE HAZARD

Before operating in a new area, check for

obstacles.

Avoid operating over large obstacles

such as rocks and fallen trees when

possible. If unavoidable, use extreme

caution and always follow proper procedures as outlined in the owner's

manual. Always have a passenger dismount before operating over an

obstacle that could cause a fall from the vehicle or vehicle tipover.

WARNING

POTENTIAL HAZARD

Skidding or sliding.

WHAT CAN HAPPEN

Skidding or sliding can cause loss of

control.

If the tires regain traction unexpectedly,

the ATV could overturn.

HOW TO AVOID THE HAZARD

On slippery surfaces such as ice, travel

slowly and use extra caution to reduce

the chance of skidding or sliding out of

control.

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SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD

Operating the ATV through deep or

fast-flowing water.

WHAT CAN HAPPEN

Tires may float, causing loss of traction

and loss of control, which could lead to

an accident or overturn.

HOW TO AVOID THE HAZARD

Avoid operating the ATV through deep

or fast-flowing water. If it's unavoidable

to enter water that exceeds the

recommended maximum depth (see

page 78), travel slowly, balance your

weight carefully, avoid sudden movements, and maintain a slow and steady

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

sudden throttle changes.

Wet brakes may have reduced stopping ability. Always test the brakes after

leaving water. If necessary, apply them several times to let friction dry out the

pads.

WARNING

POTENTIAL HAZARD

Improperly operating in reverse.

WHAT CAN HAPPEN

The ATV could collide with an obstacle

or person, resulting in severe injury.

HOW TO AVOID THE HAZARD

Before shifting into reverse gear,

always check for obstacles or people

behind the ATV. When it's safe to

proceed, back slowly.

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SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD

Operating this ATV with improper tires,

or with improper or uneven tire

pressure.

WHAT CAN HAPPEN

Use of improper tires, or operation of

the ATV with improper or uneven tire

pressure, could cause loss of control or

accident.

HOW TO AVOID THE HAZARD

Always use the size and type of tires

specified for the ATV in the owner's manual.

Always maintain proper tire pressure as described in the owner's manual and

on safety decals.

WARNING

POTENTIAL HAZARD

Operating the ATV with improper modifications.

WHAT CAN HAPPEN

Improper installation of accessories or modification of the ATV may cause

changes in handling, which could lead to an accident.

HOW TO AVOID THE HAZARD

Never modify the ATV through improper installation or use of accessories. All

parts and accessories added to the vehicle must be genuine Polaris

Industries Inc. or equivalent components designed for use on this ATV and

should be installed and used according to approved instructions. See your

authorized Polaris ATV dealer for more information.

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SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD

Overloading the ATV or carrying/towing

cargo improperly.

WHAT CAN HAPPEN

Overloading and towing can cause

changes in vehicle handling, which could

lead to loss of control or an accident.

HOW TO AVOID THE HAZARD

Never exceed the stated load capacity for

this ATV.

Cargo should be properly distributed and

securely attached.

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

distance for braking.

Always follow the instructions in the owner's manual for carrying cargo or

pulling a trailer. See page 64.

Always follow the instructions in the owner's manual for operating with a

passenger. See page 70.

WARNING

POTENTIAL HAZARD

Operating on frozen bodies of water.

WHAT CAN HAPPEN

Severe injury or death can result if

the ATV and/or riders fall through the

ice.

HOW TO AVOID THE HAZARD

Never operate the ATV on a frozen

body of water.

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SAFETY

Rider Safety

WARNING

Operating a damaged ATV can result in an accident with serious injury or

death. 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.

WARNING

Safe operation of this rider-active vehicle requires good judgement and

physical skills. Persons with cognitive or physical disabilities who operate this

vehicle have an increased risk of overturn and loss of control, which could

result in severe injury or death. Never secure a passenger to the vehicle or to

the operator with a belt, rope or similar device.

WARNING

Exhaust system components are very hot during and after use of the vehicle.

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

system components. Always keep combustible materials away from the

exhaust system. Use caution when traveling through tall grass, especially dry

grass.

WARNING

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

resulting in serious injury or death. Always remove the ignition key when the

vehicle is not in use.

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FEATURES AND CONTROLS

Switches

Worklight

Differential

Switch

Headlight

Switch

(if equipped)

4X4

Switch

Mode/Reverse

Override

Engine

Stop Switch

Main Key Switch

Switch

WARNING

Activating the override switch while the throttle is open can cause loss of

control, resulting in severe injury or death. Do not activate the override switch

while the throttle is open.

Mode/Reverse Override Switch

This vehicle is equipped with a reverse speed limiter system.To gain

additional power while backing, depress the override switch.

NOTE: The override switch also allows activation of 4X4 in reverse, if the 4X4

switch is on. This switch is also used to toggle through the modes of

the rider information center. See page 52.

Engine Stop Switch

Move the stop switch either left or right to

the OFF position to stop the engine quickly.

The engine will not start or run when the

switch is off.

OFF RUN OFF

NOTE: Both the main switch and the engine stop switch will shut off all electri-

cal power to the vehicle, including lights.

Main Key Switch

Use the main key switch to start the engine. See page 63.

4X4 Switch

Use the 4X4 switch to engage ADC 4X4, 4X4 or 2X4. See page 49.

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FEATURES AND CONTROLS

Switches

Differential Switch

Use the differential switch to lock and unlock the rear differential.

Locked Differential: Operate the vehicle with the switch in

the locked position in most conditions.

Unlocked Differential: When the differential is unlocked, the

inside wheel will rotate independently from the outside wheel

during turns. Operate with an unlocked differential only as

needed to protect smooth, level surfaces from tire damage.

Otherwise, move the switch to the locked position. This feature

will function only if the vehicle is in 2X4 mode.

WARNING

Operating with the differential unlocked ( ) when on sloped, uneven, or

loose terrain could cause loss of control and result in serious injury or death.

One rear wheel may slip and lose traction or may lift up and grab when it

touches the ground again.

^{DO NOT operate with the differential unlocked}( ) when climbing or

descending hills, when sidehilling, or when operating on uneven, loose, or

slippery terrain such as sand, gravel, ice, snow, obstacles, and water

crossings. Place the differential switch in the locked position and operate in

ADC 4X4 or 4X4 on these types of terrain.

Worklight Switch

Use the worklight switch (if equipped) to turn the worklight on or off.

The worklight is located at the rear of the vehicle. Turn the light on

while loading and unloading cargo in low light situations. Turn the

worklight off when driving.

Headlight Switch

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

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

and the engine stop switch must be in the RUN position.

WARNING

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

an accident and serious injury or death.

Your ATV is not equipped with highway-approved lights. It's designed for and

must be used for off-road use only. Use caution and drive at reduced speeds

in conditions of reduced visibility such as fog, rain and darkness.

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FEATURES AND CONTROLS

Throttle Lever

WARNING

Operating an ATV with sticking or improperly operating throttle controls could

cause an accident and lead to severe injury or death.

Never start or operate an ATV with a sticking or improperly operating throttle.

Always contact your dealer for service if throttle problems arise.

Failure to check or maintain proper operation of the throttle system can result

in an accident if the throttle lever sticks during operation. Always check the

lever for free movement and return before starting the engine. Also check

occasionally during operation.

Engine speed and vehicle move-

ment are controlled by pressing the

throttle lever. The throttle lever is

spring loaded. Engine speed returns

to idle when the lever is released.

This ATV is equipped with Polaris

Electronic Throttle Control (ETC),

which is designed to reduce the risk

of a frozen or stuck throttle. If the

throttle cable should stick in an

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

will stop, and power to the rear wheels will cease.

WARNING

Modifications to the ETC could result in failure to perform as designed, which

could result in severe injury or death. Do not attempt to modify the ETC

system or replace it with any after market throttle mechanisms. Always

ensure that the throttle cable is properly installed to the ETC.

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FEATURES AND CONTROLS

Brake Lever

Squeeze the brake lever toward the

handlebar to apply the front and

rear brakes. These brakes are

hydraulically activated disc type

brakes that are activated by only

one lever.

Always test brake lever travel and

master cylinder fluid level before

riding. When squeezed, the lever

should feel firm. Any sponginess

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

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

diagnosis and repairs.

WARNING

Operating the ATV with a spongy brake lever can result in loss of braking,

which could cause an accident. Never operate the ATV with a spongy-feeling

brake lever.

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FEATURES AND CONTROLS

Master Cylinder/Brake Fluid

Check the brake fluid in the master

cylinder before each ride. The

fluid level can be seen through an

indicator window on the top of the

master cylinder. This eye will

appear dark when the fluid level is

full. When fluid is low, the eye

will be clear.

Master Cylinder

NOTE: When checking the fluid

level, the ATV must be on

level ground with the handle-

bars straight.

Indicator

Window

If the fluid level is low add DOT 4 brake fluid only. See page 143 for the

part numbers of Polaris products.

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.

WARNING

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

meaning it rapidly absorbs moisture from the air. The moisture causes the

boiling temperature of the brake fluid to drop, which can lead to early brake

fade and the possibility of accident or severe injury. After opening a bottle of

brake fluid, always discard any unused portion.

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FEATURES AND CONTROLS

WARNING

Parking Brake

Operating the ATV while the parking brake is engaged could result in an

accident and serious injury or death. Always check to be sure the parking

brake is disengaged before operating.

Locking the Parking Brake

1. Place the transmission in

PARK.

2. Squeeze and release the brake

lever two or three times, then

squeeze and hold.

3. Push the parking brake lock

forward to engage the lock.

4. Release the brake lever.

5. To release the parking brake lock, squeeze and release the brake

lever. It will return to its unlocked position.

Important Safeguards

• 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 posi-

tion.

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

hill. Always block the wheels to prevent rolling.

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FEATURES AND CONTROLS

Auxiliary Foot Brake

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

main brake system. Should the main system fail, use the auxiliary foot

brake.

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

single lever system.

WARNING

Aggressively applying the auxiliary brake when backing down a hill may

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

down a hill.

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

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

sideways, causing loss of control and serious injury or death.

The auxiliary foot brake is located

on the inside of the right footrest.

Operate this brake with your right

foot.

Auxiliary Foot Brake

NOTE: If the rear wheels slide while

using the auxiliary brake,

reduce brake pedal pressure

to brake the rear wheels with-

out skidding.

Brake Fluid Level

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

The reservoir is located under the seat. Maintain the fluid level between

the maximum and minimum marks.

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FEATURES AND CONTROLS

Automatic Transmission Gear Selector

The transmission gear selector is

located on the right side of the vehicle.

Gear

Selector

H: High Gear

L: Low Gear

N: Neutral

R: Reverse

P: Park

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

PARK and lock the parking brake.

CAUTION

Shifting gears with the engine speed above idle or while the vehicle is moving

could cause transmission damage. To change gears, stop the vehicle, and

with the engine idling, move the lever to the desired gear.

Belt Life

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

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

time.

Fuel Filter (500 EFI)

The in-line fuel filter is located under the rubber service cover inside the

front box. Have your dealer replace the filter after every 200 hours of

operation and any time the fuel becomes contaminated with dirt or

debris. Do not attempt to clean the fuel filter.

Fuel Tank Cap

Remove the fuel tank cap to add

fuel to the fuel tank. Use either

leaded or unleaded gasoline with

a minimum pump octane number

of 87=(R+ M/2) octane. Do not

use E-85 fuel.

Fuel

Tank

Cap

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FEATURES AND CONTROLS

Recoil Starter (500 EFI)

If the battery is too weak to start

Handle

the engine, use the recoil starter.

Follow the starting procedures on

page 63, cranking the engine with

the recoil starter instead of the

main key switch.

1. Grasp the recoil starter rope

handle tightly.

2. Pull slowly so you can feel

Recoil Starter

the engine strokes.

NOTE: The rope will be harder to pull when the engine is on a compression

stroke. When a compression stroke is found, continue pulling the rope

just until the engine rolls past the stroke, then stop pulling immediately.

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

the rope abruptly and forcefully to start the engine.

4. Repeat all steps until the engine starts.

5. Make sure the handle is fully seated on the housing.

CAUTION

Extending the recoil starter rope until it stops can cause damage to the recoil

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

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

housing and damage components. Make sure the handle is fully seated on

the recoil housing, especially when traveling in wet areas.

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FEATURES AND CONTROLS

All Wheel Drive System

The All Wheel Drive system is

controlled by the 4X4 switch.

ADC 4X4 Mode

When the switch is on ADC 4X4,

the ADC system allows engine

braking to all four wheels when

the vehicle descends a hill or

incline. Always move the 4X4

switch to ADC 4X4 before

ascending or descending a hill.

See page 49.

4X4

Switch

4X4 Mode

When the switch is on 4X4, the ATV is in 4X4, and the 4X4 indicator

light in the instrument cluster will be on.

When in 4X4, the demand drive unit will automatically engage any time

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

demand drive unit will automatically disengage. There is no limit to the

length of time the vehicle may remain in 4X4.

NOTE: The override switch allows activation of 4X4 in reverse if the 4X4

switch is on. See page 38.

2X4 Mode

When the switch is on 2X4, the ATV is in two-wheel drive at all times.

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FEATURES AND CONTROLS

All Wheel Drive System

Engaging 4X4

The 4X4 switch may be turned on or off while the vehicle is moving.

Initially, the vehicle's electronic system will not enable 4X4 until the

engine RPM is below 3100. Once enabled, 4X4 remains enabled until

the 4X4 switch is turned off. If the switch is turned off while the demand

drive unit is moving, it will not disengage until the rear wheels regain

traction.

Engage the 4X4 switch before getting into conditions where front wheel

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

before switching to 4X4.

CAUTION

Switching to 4X4 or ADC 4X4 while the rear wheels are spinning may cause

severe drive shaft and gearcase damage. Always switch to 4X4 or ADC 4X4

while the rear wheels have traction or are at rest.

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FEATURES AND CONTROLS

Active Descent Control (ADC) System

The ADC system allows engine braking to all four wheels when the

vehicle descends a hill or incline. Always move the 4X4 switch to ADC

4X4 before ascending or descending a hill.

Engaging Active Descent Control

The ADC system will automatically engage when all four of the follow-

ing conditions occur:

• The 4X4 switch must be in the ADC 4X4 position

• Vehicle speed must be 15 mph (24 km/h) or less

• The throttle must be closed (throttle lever released)

• The transmission must be in gear (high, low or reverse)

Disengaging Active Descent Control

The ADC system will automatically disengage if at least one of the fol-

lowing conditions occur:

• The 4X4 switch is moved out of the ADC 4X4 position

• Vehicle speed exceeds 15 mph (24 km/h)

• The throttle is open (throttle is applied)

• The transmission is shifted to neutral or park

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FEATURES AND CONTROLS

Passenger Seat

Always make sure the passenger seat lock-out is functioning properly

before operating with a passenger.

Do not operate the vehicle with the seat in the 2-up position when oper-

ating without a passenger. Always return the seat to the 1-up position for

single-rider operation.

Never carry cargo in the rear box when operating the ATV in the 2-up

mode with a passenger.

Seat Conversion

1. Make sure the cargo box dump lever is securely latched.

2. Rotate both operator backrest latches 1/4 turn to release the locks.

3. Tilt the backrest slightly forward.

4. Pull the passenger backrest upward from the bed of the cargo box.

Operator Backrest Latches

(view from front)

Locked

Unlocked

Passenger

Backrest

Dump Lever

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FEATURES AND CONTROLS

Passenger Seat

Seat Conversion

5. Lift the adjustment latch at the top of the passenger backrest. Raise

the backrest to the desired position. Release the latch, making sure

it locks into one of the three operating positions.

NOTE: The backrest must be moved out of the lowest position before it can be

secured in the upright position. The lowest position is for seat storage

only. Do not leave the backrest in the lowest position. Always adjust

the backrest to one of the three operating positions.

6. Lower the operator

Adjustment

Backrest

backrest to create the

passenger seat. Two

retaining pins under the

seat should fit into the two

grommets on the seat

base.

Latch

Passenger

7. Test the passenger seat

lock-out by attempting to

release the cargo box

dump lever. If the dump

lever releases, the seat is

not secure. Repeat the set-

up procedure.

NOTE: If the lock-out is not working properly, do not allow a passenger to ride

the vehicle. See your Polaris dealer for service.

8. To return the vehicle to single-rider

Locked

operation, reverse all steps. Always

lower the passenger backrest to the

lowest position before folding it

down into the cargo box. Turn the

operator backrest latches 1/4 turn to

secure the locks.

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FEATURES AND CONTROLS

Instrument Cluster

Your ATV is equipped with an instrument cluster that senses vehicle

speed from a sensor in the transmission. The instrument cluster mea-

sures distance in miles as well as hours of operation. It also includes a

reverse speed limiter function that limits the ATV's speed to approxi-

mately 7-9 mph. Refer to page 38 for additional information.

Speedometer

Needle

Speedometer

Rider

Information

Center

NOTE: In addition to showing vehicle speed, the speedometer needle flashes

when a warning condition exists.

CAUTION

High water pressure may damage ATV components. Wash the ATV by hand

or with a garden hose using mild soap.

Certain products, including insect repellents and chemicals, will damage the

speedometer lens and other plastic surfaces. Do not use alcohol to clean the

instrument cluster. Do not allow insect sprays to contact the lens.

Immediately clean off any gasoline that splashes on the instrument cluster.

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FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

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

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

NOTE: If the instrument cluster fails to illuminate, a battery over-voltage may

have occurred and the instrument cluster may have shut off to protect

the electronic speedometer. If this occurs, take the ATV to your Polaris

dealer for proper diagnosis.

1. Gear Indicator - This

indicator displays gear

shifter position:

H = High Gear

L = Low Gear

N = Neutral

R = Reverse Gear

P = Park

2. 4X4 Indicator - This

indicator illuminates

when the 4X4 switch

is on either ADC 4X4

or 4X4.

3. Engine Hour Display Indicator

4. Service Interval/Diagnostic Mode Indicator

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

that the ATV is operating at an RPM too low to keep the battery

charged. It may also occur when the engine is at idle and high elec-

trical load (lights, cooling fan, accessories) is applied. Drive at a

higher RPM or recharge the battery to clear the warning.

6. Odometer/Tachometer/Tripmeter/ Hour Meter/Clock

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

in the fuel tank. When the last segment clears, a low fuel warning is

activated. All segments will flash, FUEL will display in the LCD,

and the speedometer needle will blink. Refuel immediately.

8. Check Engine Warning Indicator - This indicator serves two pur-

poses. The word HOT displays if the engine overheats. It also

appears if an EFI-related fault occurs. Do not operate the ATV if

this warning appears. Serious engine damage could result.

9. Mode Indicator

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FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Standard Modes

Use the MODE button to toggle through the mode options. The reverse

override button is also the MODE button. See page 38.

NOTE: The transmission cannot be in reverse when using this feature.

Odometer Mode

The odometer records the miles traveled by the ATV.

Trip Meter Mode

The trip meter records the miles traveled by the ATV on each trip if it's

reset before each trip. To reset the trip meter, select the trip meter mode.

Press and hold the mode button (override button) until the total changes

to 0.

NOTE: In the Rider Information Center, the trip meter display contains a deci-

mal point, but the odometer displays without a decimal point.

Hour Meter Mode

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

Tachometer Mode

The engine RPM is displayed digitally.

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

of changes in humidity, temperature and elevation.

Clock Mode

The clock displays time in a 12-hour format. To reset the clock, see page

55.

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FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

The wrench icon will display when the gauge is in the diagnostic mode.

To exit the diagnostic mode, turn the key switch off and on. Any move-

ment of the tires will also cause the gauge to exit the diagnostic mode.

To enter the diagnostics mode:

1. Turn the key switch off and wait 10 seconds.

2. Lock the parking brake.

3. Place the transmission in neutral.

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

Release the switch as soon as the display is activated.

5. Use the mode button to toggle through the diagnostic screens.

Clock Screen

To reset the clock:

1. Enter the diagnostic mode.

2. Toggle to the clock screen.

3. Press and hold the mode button until the hour display flashes.

Release the button.

4. Press and release the mode button once to advance the setting by

one hour. Press and hold the mode button to advance the hours

quickly.

5. When the desired hour is displayed, wait approximately four sec-

onds, until the minute display flashes.

6. Use the same procedure to reset the minutes.

7. When the display stops flashing, the mode has been set.

NOTE: Do not turn the key switch off until the display stops flashing or

the new setting will not be locked into the memory.

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FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

Battery Voltage Screen

View this screen to check battery voltage level.

Tachometer Screen

View the tachometer to check engine speed.

4X4 Diagnostic Screen

The gauge indicates whether or not current is flowing through the all

wheel drive coil. This screen is for informational purposes only. Please

see your dealer for all major repairs.

Gear Circuit Diagnostic Screen

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

gear switch input of the gauge. This screen is for informational purposes

only. Please see your dealer for all major repairs.

Programmable service interval

When the hours of engine operation equal the programmed service

interval setting, the wrench icon will flash for 5 seconds each time the

engine is started. When this feature is enabled, it provides a convenient

reminder to perform routine maintenance. See page 57.

NOTE: The service interval is programmed at 50 hours at the factory.

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FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

Programmable service interval

To enable or disable the service interval:

1. Enter the diagnostic mode.

2. Toggle to the service interval screen.

3. Press and hold the mode button for about 7 seconds, until either ON

or OFF appears in the Rider Information Center, depending on your

preference.

To reset the service interval:

1. Enter the diagnostic mode.

2. Toggle to the service interval screen.

3. Press and hold the mode button for 2-3 seconds, until the wrench

icon flashes. Release the button.

4. Press and release the mode button once to advance the setting by

one hour. Press and hold the mode button to advance the hours

quickly.

NOTE: If you scroll past the intended number, press and hold the button until

the hours cycle back to zero.

5. When the desired setting is displayed, wait until the wrench icon

stops flashing. The new service interval is now programmed.

Miles/Kilometers toggle

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

either standard or metric units of measurement.

1. Enter the diagnostic mode.

2. Toggle to the screen that displays either kilometers (KM) or miles

(MP).

3. Press and hold the mode button until the letters flash, then press and

release the button once. When the display stops flashing, the mode

has been set.

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FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Downloading Codes

The EFI diagnostic mode is for informational purposes only. Please see

your Polaris dealer for all major repairs.

See page 59 for Blink Codes and Failure Descriptions. Use the follow-

ing procedure to download blink codes (failure codes) from the EFI

module.

1. Place the transmission in PARK. Stop

the engine. Turn the key switch to the

ON position.

2. Turn the key switch off and on three

times in less than five seconds. The

word “WAIt” will appear on the screen.

3. The Check Engine icon will blink once, pause, then blink twice

(blink code 12) to begin the diagnostic sequence. The EFI module is

now searching for blink codes. If a code exists, the Check Engine

icon will flash the code.

4. Count the number of times the Check Engine icon flashes.

Example: For the two blink codes 42 and 36, the Check Engine icon will

flash 4 times, pause, then flash 2 times (code 42), then pause longer,

blink 3 times, pause, and blink 6 times (code 36).

5. A code 61 will signal the end of the sequence. If no blink codes are

found, only codes 12 and 61 will appear during the sequence.

NOTE: The word “WAIt” will remain on the screen through this entire process.

Code Definitions

Open Load: There is a break in the wires that lead to the item listed in

the chart (injector, fuel pump, etc.), or the item has failed.

Short-to-Ground: The wire is shorted to ground between the electronic

control unit and the item listed in the chart.

Shorted Load: The wires leading to the item listed in the chart are

shorted together, or the item has shorted internally.

Short-to-Battery: The wire leading from the item listed in the chart to

the electronic control unit is shorted to a wire at battery voltage.

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FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Downloading Codes

Blink

Code

Failure Description

BEGIN SEQUENCE

Throttle Position Sensor Low

Throttle Position Sensor High

Gear Sensor Signal

System Voltage Low

System Voltage High

Ignition Coil A Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground

Ignition Coil A Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery

Ignition Coil B Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground

Ignition Coil B Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery

Air Temp Sensor Low Voltage

Air Temp Sensor High Voltage

Engine Coolant Temp Low Voltage

Engine Coolant Temp High Voltage

Crank Position Sensor Circuit Fault

Barometric Pressure/Manifold Air Pressure Sensor Low

Barometric Pressure/Manifold Air Pressure Sensor High

IAC Stepper Motor: Open Load

IAC Stepper Motor: Short-to-Ground

Injector Circuit Malfunction - Cyl 1: Open Load/Short-to-Ground

Injector Circuit Malfunction - Cyl 1: Shorted Load/Short-to-Battery

Injector Circuit Malfunction - Cyl 2: Open Load/Short-to-Ground

Injector Circuit Malfunction - Cyl 2: Shorted Load/Short-to-Battery

MIL Circuit: Open Load/Short-to-Ground

MIL Circuit: Shorted Load/Short-to-Battery

Fuel Pump: Open Load/Short-to-Ground

Fuel Pump: Shorted Load/Short-to-Battery

Fan Circuit: Open Load/Short-to-Ground

Fan Circuit: Shorted Load/Short-to-Battery

ADC: Open Load/Short-to-Ground

ADC: Shorted Load/Short-to-Battery

Starter Enable: Open Load/Short-to-Ground

Starter Enable: Shorted Load/Short-to-Battery

Gear Sensor Signal

4X4: Open Load/Short-to-Ground

4X4: Shorted Load/Short-to-Battery

Rear Differential Enable: Open Load/Short-to-Ground

Rear Differential Enable: Shorted Load/Short-to-Battery

END SEQUENCE

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OPERATION

Fuel Safety

WARNING

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

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

area.

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

refueling is performed or where gasoline is stored.

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

• If gasoline spills on your skin or clothing, immediately wash it off with soap

and water and change clothing.

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

fumes are poisonous and can cause loss of consciousness or death in a

short time.

WARNING

The engine exhaust from this product contains chemicals known to cause

cancer, birth defects or other reproductive harm.

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

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OPERATION

Break-In Period

The break-in period for your new Polaris ATV is the first ten hours of

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

No single action on your part is as important as following the proce-

dures for a proper break-in. Careful treatment of a new engine and drive

components will result in more efficient performance and longer life for

these components.

CAUTION

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

close-fitted engine parts and drive components. Do not operate at full throttle

or high speeds during the first three hours of use.

Engine and Drivetrain Break-in

1. Fill the fuel tank with gasoline. See page 45.

2. Check the engine oil level on the dipstick. See page 90. Add oil if

necessary to maintain the level between the safe and add marks.

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

iarize yourself with vehicle operation and handling.

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

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

on the daily pre-ride inspection checklist. See page 62.

6. Pull only light loads.

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

hours or one month.

PVT Break-in (Clutches/Belt)

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

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

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

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

ing the break-in period.

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OPERATION

Pre-Ride Checklist

WARNING

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

could result. Always inspect the vehicle before each use to ensure it's in

proper operating condition.

Item

Remarks

Page

Passenger seat lock-out

Brake system/lever travel

Ensure proper operation

104

Brake fluid

Ensure proper level

Auxiliary brake

Front suspension

Rear suspension

Steering

Ensure proper operation

Inspect, lubricate if necessary

Ensure free operation

Tires

Inspect condition and pressure

Inspect, ensure fastener tightness

107

Wheels/fasteners

107

108

Frame nuts, bolts, fasteners Inspect, ensure tightness

Fuel and oil

Ensure proper levels

Coolant level (if applicable)

Ensure proper level

102

103

Coolant hoses (if applicable) Inspect for leaks

Throttle

Ensure proper operation

138

Indicator lights/switches

Engine stop switch

Air filter, pre-filter

Air box sediment tube

Headlamp

Ensure operation

109

Ensure proper operation

Inspect, clean

Drain deposits whenever visible

Check operation, apply Polaris dielec-

tric grease when lamp is replaced

112

Brake light/taillight

Riding gear

Check operation, apply Polaris dielec-

tric grease when lamp is replaced

115

Wear approved helmet, goggles, and

protective clothing

ADC Fluid

Ensure proper level

100

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OPERATION

Starting the Engine

WARNING

Engine exhaust contains poisonous carbon monoxide and can cause loss of

consciousness resulting in severe injury or death. Never run an engine in an

enclosed area.

1. Position the vehicle on a level surface.

2. Place the transmission in PARK.

3. Lock the parking brake.

NOTE: The starter interlock will prevent the engine from starting if the trans-

mission is in gear and the brake is not engaged.

4. Sit on the vehicle and move the engine stop switch to RUN.

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

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

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

key when the engine starts.

500 EFI ONLY: The starter will automatically stop if engaged for longer than

5 seconds. Move the key to the OFF position and wait 10 seconds before

engaging the starter again.

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

wait five seconds before attempting to start again. Activate the

starter for another five seconds if necessary. Repeat this procedure

until the engine starts.

CAUTION

Operating the vehicle immediately after starting could cause engine damage.

Allow the engine to warm up for several minutes before operating the vehicle.

Cold Weather Operation

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

level could indicate the accumulation of contaminates such as water or

excess fuel in the bottom of the crankcase. Water in the bottom of the

crankcase can lead to engine damage and must be drained. Water accu-

mulation increases as outside temperature decreases.

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

warm-ups and easier starting in colder weather.

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OPERATION

Hauling Cargo

WARNING

Overloading the vehicle or carrying or towing cargo improperly can alter

vehicle handling and may cause loss of control or brake instability. Always

follow these precautions when hauling cargo:

Never exceed the stated load capacity for this vehicle.

Never carry cargo in the rear box when operating the ATV in the 2-up mode

with a passenger.

REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING

WHEN HAULING CARGO.

REDUCE SPEED AND CARGO to maintain stable driving conditions when

operating over rough or hilly terrain.

WEIGHT DISTRIBUTION in the cargo bed should be as far forward and as

low as possible. Carrying a high load raises the center of gravity and creates

a less stable operating condition. Reduce load weight when cargo is high.

When handling off-centered loads that cannot be centered, secure the load

and operate with extra caution.

SECURE ALL LOADS BEFORE OPERATING. Unsecured loads may shift

and create unstable operating conditions, which could result in loss of control

of the vehicle. Always be sure that the cargo bed is lowered and latched

before moving the vehicle.

USE EXTREME CAUTION when operating with loads extending beyond the

rack or cargo bed. Stability and maneuverability may be adversely affected,

causing the machine to overturn.

BALANCE LOADS proportionally between the front rack and cargo bed, but

do not exceed the stated load capacity. Carrying a load on only the front rack

or cargo bed may cause an imbalanced condition and increases the

possibility of vehicle overturn.

USE EXTREME CAUTION when applying brakes with a loaded vehicle.

Avoid terrain or situations that may require backing downhill.

Always attach the tow load to the hitch point.

DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. The

vehicle should never exceed 10 mph (16 kph) while towing a load on a level

surface. Vehicle speed should never exceed 5 mph (8 kph) when towing

loads in rough terrain, while cornering, or while ascending or descending a

hill.

DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on

the front rack.

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OPERATION

Hauling Cargo

Your ATV has been

designed to carry or tow a

certain amount of load.

Always read and understand

the load distribution warn-

ing labels on the vehicle,

and never exceed the weight

capacities outlined in the

specifications section of the

owner's manual and on the

safety decals.

Cargo weight should be

mounted as low as possible.

When operating over rough

or hilly terrain, reduce speed

and cargo weight to maintain stable driving conditions. Do not obstruct

the headlight beam with cargo. Use low forward gear when hauling or

towing heavy cargo to extend belt life.

1. Always load the cargo box with the load as far forward as possible.

2. Always operate the vehicle with extreme caution whenever hauling

or towing loads. Balance, handling, and control may be affected.

3. Slow down.

4. Make sure the cargo box dump latch is securely latched before load-

ing and operating. Unintentional dumping will result if weight is

placed in the rear of the box and the latch is not secured.

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OPERATION

Hauling Cargo

Towing Loads

Always attach a towed load to the hitch point. If towing a load, reduce

rear box cargo weight by the amount of tongue weight. The combination

of rear box cargo weight and tongue weight must not exceed the rear

box capacity.

CAUTION

Using an improper hitch or exceeding

the maximum tongue weight capacity

can result in serious damage to the

vehicle and will void your ATV warranty.

Never install a hitch longer than 6 3/4"

(17 cm). Never install automotive

accessories on your Polaris ATV. Always

install Polaris-approved (or equivalent)

accessories designed for ATV use.

Maximum

6 3/4" (17 cm)

Maximum Towing Capacities

Do not exceed the following maximum capacities when towing. Avoid

towing on inclines.

500 EFI

1225 lbs. (557 kg)

120 lbs. (55 kg)

700/800 EFI

1500 lbs. (680 kg)

150 lbs. (68 kg)

Maximum Towed Load (Level Ground)

Maximum Vertical Hitch Weight

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OPERATION

Hauling Cargo

Dumping Cargo

1. Select a level site to dump the cargo box. Do not attempt to dump or

unload the vehicle while parked on an incline.

2. Place the transmission in PARK.

3. Lock the parking brake.

4. Dismount the vehicle.

5. Lower the tailgate.

WARNING

If cargo weight is placed toward the rear of the cargo box, the load may dump

unexpectedly and cause serious injury. When loading cargo, always position

the weight as far forward and as low as possible.

6. Pull the cargo box release lever

upward.

7. Lift the front of the cargo box

and dump the cargo.

Dump Box

Release

Latch

8. Lower the cargo box and make

sure the release latch is

secured.

9. Secure the tailgate.

WARNING

Operating with the cargo box in the raised position can cause serious injury

and damage to the vehicle. The cargo box could close unexpectedly and

injure the driver. The rear tires will also catch the rear of the bed, damaging

the vehicle and creating hazardous driving conditions.

Never operate this vehicle with the cargo box in the raised position.

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OPERATION

Driving Procedures

1. Wear protective riding gear. See page 12.

2. Perform the pre-ride inspection. See page 62.

3. Place the transmission in PARK.

4. Lock the parking brake.

5. Mount the vehicle from the left side.

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

handlebars.

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

8. Shift the transmission into gear.

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

10. Release the parking brake.

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

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

brakes on level surfaces.

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OPERATION

Turning the Vehicle

Both rear wheels drive

equally at all times (except

when operating in 2X4 mode

with the differential

unlocked). This means that

the outside wheel must travel

a greater distance than the

inside wheel when turning,

and the inside tire must slip

traction slightly.

1. Slow down.

2. Never turn quickly when

carrying a passenger or

cargo.

3. Steer in the direction of

the turn.

4. Keep both feet on the footrests.

5. Lean your upper body to the inside of the turn while supporting your

weight on the outer footrest.

NOTE: This technique alters the balance of traction between the rear wheels,

allowing the turn to be made smoothly.

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

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

faster speeds.

WARNING

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

and lead to serious injury. Avoid turning at sharp angles. Never turn at high

speeds.

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OPERATION

Driving with a Passenger

1. Make sure the passenger is at least

12 years of age and is tall enough to

comfortably reach the footrests and

grab handles.

NOTE: Footwell risers should be installed

for smaller passengers. Please

see your Polaris dealer about

installing or purchasing a footwell

riser kit.

Footwell

Riser

2. Make sure the passenger is wearing appropriate riding gear, includ-

ing an approved helmet with a rigid chin guard. See page 12.

3. Perform the pre-ride

inspection. See page 62.

4. Convert the seat for 2-up

riding. See page 50.

Make sure the passenger

seat lock-out is function-

ing properly.

5. Lock the parking brake.

6. Mount the vehicle from

the left side. After the

operator is seated, the

passenger should mount

the vehicle from the left

side. Always make sure

the brake is engaged to

ensure the vehicle

remains motionless whenever a passenger mounts or dismounts.

7. Allow a passenger to ride only in the approved passenger seat.

8. Do not carry more than one passenger.

9. Slow down. Control may be more difficult with a passenger on

board. Allow more time and distance for braking.

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OPERATION

Driving with a Passenger

10. Ride to the ability of your passenger, instead of to your own ability.

Avoid unexpected or aggressive maneuvers that could cause a pas-

senger to fall from the vehicle.

11. Do not cross a hillside with a passenger on board. See page 74.

12. A passenger should always be seated in the passenger seat with both

feet on the footrests and both hands on the passenger grab handles

at all times. The passenger should never hold on to the operator.

13. Never secure a passenger to the vehicle or to the operator with a

belt, rope or similar device.

14. Make sure the passenger understands the importance of "active

riding." When hill-climbing or performing maneuvers, a passenger

should shift body weight in the same manner in which the driver

shifts body weight. For example, the passenger should lean to the

inside of a turn along with the operator and should always lean

uphill when climbing and descending hills.

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OPERATION

Driving on Slippery Surfaces

Whenever riding on slippery

surfaces such as wet trails or

loose gravel, or during freez-

ing weather, follow these

precautions:

1. Slow down when enter-

ing slippery areas.

2. Engage 4X4 before

wheels begin to lose

traction.

3. Maintain a high level of

alertness, reading the

trail and avoiding quick,

sharp turns, which can

cause skids.

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

and shifting your body weight forward.

CAUTION

Severe damage to drive train may occur if 4X4 is engaged while the wheels

are spinning. Always allow the rear wheels to stop spinning before engaging

4X4, or engage 4X4 before wheels begin to lose traction.

WARNING

Failure to exercise care when operating on slippery surfaces can result in

loss of tire traction and cause loss of control, accident, and serious injury or

death.

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

surfaces. Always reduce speed and use additional caution.

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OPERATION

Driving Uphill

15° Maximum

Whenever traveling uphill, follow these precautions:

1. Always move the 4X4 switch to ADC 4X4 before ascending or

descending a hill. See page 49.

2. Drive straight uphill.

3. Avoid steep hills (15° maximum).

4. Keep both feet on the footrests.

5. Shift body weight uphill.

6. Proceed at a steady rate of speed and throttle opening.

7. Remain alert and be prepared to take emergency action. This may

include quick dismounting of the vehicle.

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

hill! Apply the hand brake. If a passenger is on board, ask the pas-

senger to dismount. Use the K-turn to turn around. See page 76.

WARNING

Braking and handling are greatly affected when operating in hilly terrain.

Improper procedure could cause loss of control or overturn and result in

serious injury or death.

Avoid climbing steep hills (15° maximum).

Use extreme caution when operating on hills, and follow proper operating

procedures outlined in the owner's manual.

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OPERATION

Driving on a Sidehill (Sidehilling)

WARNING

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

vehicle overturn, resulting in severe injury or death. Avoid crossing the side

of a hill when possible. Do not cross a hillside with a passenger on board.

Follow proper procedures as outlined in the owner's manual.

Sidehilling can be dangerous and should be avoided if at all possible. If

you encounter a situation where sidehilling is necessary, follow these

precautions:

1. Slow down.

2. If operating in 2X4 mode, make sure the differential is locked.

3. Do not cross a hillside with a passenger on board. Ask the passenger

to dismount and walk across the hillside before remounting the

vehicle.

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

hill while keeping your feet on the footrests.

5. Steer slightly into the hill to maintain vehicle direction.

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

possible, or dismount on the uphill side immediately!

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OPERATION

Driving Downhill

15° Maximum

WARNING

Excessive speed when traveling downhill can cause loss of control and

serious injury or death. Slow down.

Applying the brakes too firmly may cause the rear wheels to lock, which

could result in loss of control and serious injury or death. Apply the brakes

gradually.

When driving downhill, follow these precautions:

1. Always move the 4X4 switch to ADC 4X4 before ascending or

descending a hill. See page 49.

2. Always descend a hill with the transmission in forward gear. Do not

descend a hill with the transmission in neutral.

3. Slow down.

4. Proceed directly downhill.

5. Shift body weight uphill.

6. Apply the brakes slightly to aid in slowing.

NOTE: Before operating your ATV, learn how to use the auxiliary brake for

emergency situations (if single-lever brakes become inoperable).

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OPERATION

Turning Around on a Hill (K-Turn)

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

Use the K-turn to turn around.

8 ft. (2.4 m)

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OPERATION

Turning Around on a Hill (K-Turn)

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

2. Always move the 4X4 switch to ADC 4X4 before ascending or

descending a hill. See page 49.

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

4. If a passenger is on board, ask the passenger to dismount first, then

the operator may dismount. Dismount on the uphill side of the vehi-

cle, or on the left if the vehicle is pointing straight uphill.

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

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

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

ing across the hill or slightly downward.

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

keeping body weight uphill.

NOTE: A passenger should not remount until the vehicle returns to firm, level

ground.

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

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

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

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OPERATION

Driving Through Water

Maximum

Depth

Your ATV can operate through water with a maximum recommended

depth equal to the bottom of the footrests. Follow these procedures

when operating through water:

1. Determine water depths and current before crossing.

2. Choose a crossing where both banks have gradual inclines.

3. Proceed slowly, avoiding rocks and obstacles.

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

until braking action is normal.

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OPERATION

Driving Through Water

After running the vehicle in water, it's critical to have it serviced as out-

lined in the maintenance chart. See page 85. The following areas need

special attention: engine oil, transmission oil, demand drive fluid and all

grease fittings.

CAUTION

Major engine damage can result if the vehicle is not thoroughly inspected

after operation in water. Perform the services outlined in the maintenance

chart.

If your vehicle becomes immersed or is operated in water that exceeds the

footrest level, take it to your dealer for service before starting the engine.

NOTE: Avoid operating the vehicle through deep or fast-flowing water. If you

cannot avoid water that exceeds the recommended maximum depth,

go slowly, balance your weight carefully, avoid sudden movements,

and maintain a slow and steady forward motion. Do not make sudden

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

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

dealer before starting it, follow the steps described on page 118. Have

the vehicle serviced by your dealer at the first opportunity.

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OPERATION

Driving Over Obstacles

1. Be alert! Look ahead and learn to read the terrain you're traveling

on. Be constantly alert for hazards such as logs, rocks and low hang-

ing branches.

2. Avoid operating over large obstacles such as rocks and fallen trees

when possible. If unavoidable, use extreme caution.

3. Always have a passenger dismount before operating over an obsta-

cle that could cause a fall from the vehicle or vehicle tipover.

WARNING

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

hidden obstacle. Not all obstacles are immediately visible. Travel with caution

in unfamiliar terrain.

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OPERATION

Parking on an Incline

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

precautions:

1. Stop the engine.

2. Place the transmission in PARK.

3. Lock the parking brake.

4. Always block the rear wheels on the downhill side.

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OPERATION

Driving in Reverse

WARNING

Failure to use caution when operating in reverse can result in serious injury

or death. Before shifting into reverse, always check for obstacles or people

behind the vehicle. When it's safe to proceed, back slowly.

Do not use the override switch unless additional power is required for vehicle

movement. Use with caution.

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

CAUTION

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

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

Operate the throttle just enough to maintain a desired speed

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OPERATION

Driving in Reverse

Follow these precautions when operating in reverse:

1. Always check for obstacles or people behind the vehicle. Be aware

that a passenger can obstruct your view.

2. Always avoid backing downhill.

3. Back slowly.

4. Apply the brakes lightly for stopping.

5. Avoid turning at sharp angles.

6. Never open the throttle suddenly.

NOTE: Your Polaris ATV is equipped with a reverse speed limiter. Use the

override button with caution as rearward vehicle speed is greatly

increased. Do not operate at wide open throttle. Apply just enough

throttle to maintain a desired speed.

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EMISSION CONTROL SYSTEMS

Noise Emission Control System

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

may affect compliance with U.S.A. EPA noise control requirements (40

CFR 205) and local noise level requirements.

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

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

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

eral law requires that this spark arrestor be installed and functional when

the vehicle is operated on public lands.

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

by 43 CFR 8343. Violations are subject to monetary penalties. Federal

regulations can be viewed online at www.gpoaccess.gov/ecfr/.

Crankcase Emission Control System

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

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

exhaust gases exit through the exhaust system.

Exhaust Emission Control System

Exhaust emissions are controlled by engine design. An electronic fuel

injection (EFI) system controls fuel delivery. The engine and EFI com-

ponents are set at the factory for optimal performance and are not

adjustable.

The emissions label is located on the battery box.

Electromagnetic Interference

This spark ignition system complies with Canadian ICES-002.

This vehicle complies with European directives 97/24/EC and 89/336/

EEC.

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MAINTENANCE

Periodic Maintenance Chart

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

most reliable condition. Inspection, adjustment and lubrication of

important components are explained in the periodic maintenance chart.

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

inspection reveals the need for replacement parts, use genuine Polaris

parts available from your Polaris dealer.

Record maintenance and service in the Maintenance Log beginning on

page 156.

NOTE: Service and adjustments are important for proper vehicle operation. If

you're not familiar with safe service and adjustment procedures, have

a qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average

riding conditions and an average vehicle speed of approximately 10

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

serviced more frequently.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation

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

weather can indicate contaminants collecting in the oil sump or crank-

case. Change oil immediately if the oil level begins to rise. Monitor the

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

cause or see your dealer.

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MAINTENANCE

Periodic Maintenance Chart

Maintenance Chart Key

Perform these operations more often for vehicles subjected to

severe use.

Emission-related service (Failure to conduct this maintenance will

not void the emissions warranty but may affect emissions.)

Have an authorized Polaris dealer perform these services.

WARNING

Improperly performing the procedures marked with a Q could result in

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

Polaris dealer perform these services.

Perform all services at whichever maintenance interval is reached first.

Item

Maintenance Interval

Remarks

(whichever comes first)

Hours Calendar

Miles

(Km)

Steering

Pre-Ride

Make adjustments as

needed. See Pre-Ride

Checklist on page 62.

Front suspension

Rear suspension

Tires

Brake fluid level

Brake lever travel

Brake system

Passenger seat

lock-out

Wheels/fasteners

Frame fasteners

Engine oil level

Pre-Ride

Daily

X Air filter, pre-filter

Inspect; clean often; replace

as needed

X Air box sediment

Daily

Drain deposits when visible

tube

Coolant

(if applicable)

Check level daily, change

coolant every 2 years

X ADC fluid

Check level daily, add as

needed

(ADC models)

Headlight/taillight/

worklight

Check operation; apply

dielectric grease if replacing

lamps

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MAINTENANCE

Periodic Maintenance Chart

Item

Maintenance Interval

Remarks

(whichever comes first)

Hours Calendar

Miles

(Km)

X Air filter,

Weekly

Inspect; replace as needed

E main element

Recoil housing

(if applicable)

Drain water as needed,

check often if operating in wet

conditions

X Brake pad wear

10 H

Monthly

100 (160) Inspect periodically

Battery

20 H

25 H

Monthly

200 (320) Check terminals; clean; test

250 (400) Inspect level; change yearly

X Rear gearcase oil

(if equipped)

X Transmission oil

25 H

Monthly

250 (400) Inspect level; change yearly

250 (400) Inspect; clean if needed

X Demand drive fluid 25 H

X Engine breather

E filter (if equipped)

25 H

X General

50 H

3 M

500 (800) Lubricate all fittings, pivots,

cables, etc.

lubrication

Shift linkage

50 H

6 M

500 (800) Inspect, lubricate

500 (800) Lubricate

Steering

X Front suspension

X Rear suspension

Throttle Cable/

ETC Switch

500 (800) Inspect; adjust; lubricate;

replace if necessary

E Throttle Body

50 H

6 M

500 (800) Inspect duct for proper seal-

ing/air leaks

Intake Duct

Drive belt

500 (800) Inspect; adjust; replace as

needed

Cooling system

(if applicable)

1000 (1600) Inspect coolant strength

seasonally; pressure test

system yearly

X Engine oil change 100 H

X Oil filter change 100 H

6 M

1000 (1600) Perform a break-in oil change

at one month

1000 (1600) Replace with oil change

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MAINTENANCE

Periodic Maintenance Chart

Item

Maintenance Interval

Remarks

(whichever comes first)

Hours Calendar

Miles

(Km)

Valve clearance

Fuel system

100 H

12 M

1000 (1600) Inspect; adjust

1000 (1600) Check for leaks at tank cap,

lines, filter, pump; replace

lines every two years

X Radiator

(if applicable)

100 H

12 M

1000 (1600) Inspect; clean external

surfaces

X Cooling hoses

1000 (1600) Inspect for leaks

(if applicable)

X Engine mounts

100 H

12 M

1000 (1600) Inspect

Exhaust muffler/

pipe

Spark plug

100 H

12 M

1000 (1600) Inspect; replace as needed

X Wiring

1000 (1600) Inspect for wear, routing,

security; apply dielectric

grease to connectors

subjected to water, mud, etc.

Clutches (drive

100 H

12 M

1000 (1600) Inspect; clean; replace worn

parts

and driven)

Front wheel

bearings

1000 (1600) Inspect; replace as needed

Brake fluid

200 H

24 M

2000 (3200) Change every two years

ADC fluid

(ADC models)

X Fuel filter

200 H

24 M

2000 (3200) Check for leaks around lines.

Replace every 2 years, more

often under

extreme conditions.

Spark arrestor

300 H

36 M

3000 (4800) Clean out

Toe adjustment

Inspect periodically; adjust

when parts are replaced

Headlight aim

Adjust as needed

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

E Emission-Related Service

Q Have an authorized Polaris dealer perform these services.

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MAINTENANCE

Lubrication Guide

Check and lubricate all components at the intervals outlined in the

Periodic Maintenance Chart beginning on page 85. Items not

listed in the chart should be lubricated at the General Lubrication

interval.

NOTE: The a-arms and upper control arms are lubricated at the factory, and

no additional lubrication will be needed. However, if these components

are subjected to severe use, grease zerks have been provided for

additional lubrication at the user's discretion.

Item

Lube

Capacity at

Fluid Change

Inspection Procedure

Engine Oil

PS-4 PLUS

Performance

Synthetic 2W-50

2 qt. (1.9 l)

See page 90.

Brake Fluid

DOT 4 Only

---

See page 42.

Transmission Oil

Polaris AGL Syn-

thetic

Gearcase Lube

32 oz. (948 ml) See page 98.

Demand Drive

Fluid

(Front Gearcase)

Demand Drive LT

Premium Fluid

9.3 oz. (275 ml) See page 99.

ADC Fluid

Polaris ADC Fluid

---

See page 100.

Front Prop Shaft

Yoke

Polaris Premium

U-Joint Lube

Grease fittings (3 pumps

maximum) every 500 miles,

before long periods of stor-

age, or after pressure wash-

ing or submerging.

Front Prop Shaft Yoke

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MAINTENANCE

Engine Oil

Oil Recommendations

Polaris recommends the use of Polaris PS-4 PLUS Performance Syn-

thetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may need to

be changed more frequently if Polaris oil is not used. Always use 2W-50

oil. Follow the manufacturer's recommendations for ambient tempera-

ture operation. See page 143 for the part numbers of Polaris products.

CAUTION

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

damage. Always use the recommended oil. Never substitute or mix oil

brands.

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MAINTENANCE

Engine Oil

Oil Level (500 EFI)

Access the oil dipstick and fill tube

from the left side of the ATV.

NOTE: A rising oil level between

checks in cool weather driving

can indicate contaminants

such as gas or moisture col-

lecting in the crankcase. If the

oil level is over the full/safe

mark, change the oil immedi-

ately.

Dipstick

1. Position the vehicle on a level

surface.

2. Start the engine. Allow it to idle

for 20-30 seconds. Stop the

engine.

Safe Range

3. Remove the dipstick. Wipe it

dry with a clean cloth.

Safe

Add Oil

4. Reinstall the dipstick

completely.

5. Remove the dipstick and check

the oil level. Maintain the oil

level in the safe range. Do not

overfill.

6. Reinstall the dipstick securely.

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MAINTENANCE

Engine Oil

Oil Level (700/800 EFI)

Access the oil dipstick and fill tube

from the left side of the ATV.

Dipstick

1. Position the vehicle on a level

surface.

2. Lift the lever lock to remove

the dipstick. Wipe it dry with a

clean cloth.

3. Reinstall the dipstick com-

pletely, but do not lock it.

NOTE: The dipstick must be inserted

completely to keep the angle

and depth of the stick consis-

tent.

4. Remove the dipstick and check

the oil level. Maintain the oil

level in the safe range. Do not

overfill.

NOTE: Due to the dipstick entry angle

into the crankcase, the oil

Safe

Add Oil

Safe

Range

level will read higher on the

bottom side of the dipstick.

Always read the level on the

upper surface of the dipstick.

Check Level

on Top Side

5. After reinstalling the dipstick,

seat the lever lock.

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MAINTENANCE

Engine Oil

Oil and Filter Change (500 EFI)

CAUTION

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

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

Maintenance Chart beginning on page 85.

1. Position the vehicle on a level surface.

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

3. Stop the engine.

4. Clean the area around the drain

plug.

5. Place a drain pan under the oil

tank.

Screen

Fitting

Drain

Plug

6. Remove the drain plug. Allow

the oil to drain completely.

7. Install a new sealing washer on

the drain plug.

New Sealing Washer

NOTE: The sealing surfaces on drain

plug and crankcase should be

clean and free of burrs, nicks

or scratches.

8. Reinstall the drain plug. Torque

to 14-17 ft. lbs. (19-23 Nm).

9. Disconnect the lower oil deliv-

ery hose and remove the screen

fitting from the oil tank. Clean

the fitting.

Alignment Mark

NOTE: The fitting threads must be sealed with LOCTITE PST 505 or PTFE

seal tape.

10. Reinstall the screen fitting and rotate the fitting clockwise a mini-

mum of 2 1/2 turns into the tank threads. Continue to rotate the fit-

ting until the nipple of the fitting aligns with the mark on the tank.

NOTE: Do not over-tighten. Maximum torque for the screen fitting is 25 ft. lbs.

(34 Nm).

11. Reattach the oil line.

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MAINTENANCE

Engine Oil

Oil and Filter Change (500 EFI)

12. Place shop towels beneath the oil

filter. Using an oil filter wrench,

turn the filter counterclockwise to

remove it.

13. Make sure the o-ring from the old

filter is completely removed from

the engine. Using a clean dry

cloth, clean the filter sealing sur-

face on the crankcase.

14. Lubricate the o-ring on the new filter with a film of fresh engine oil.

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

15. Install the new filter and rotate it clockwise by hand until the filter

gasket contacts the sealing surface, then turn it an additional 1/2

turn.

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

To drain, remove the drain plug on the lower right side of the crank-

case.

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

and free of burrs, nicks or scratches.

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

18. Remove the dipstick.

19. Add two quarts (1.9 l) of recommended oil. Reinstall the dipstick.

NOTE: If the sump is not drained, add about 1 3/4 quarts (1.6 l) initially.

20. Place the transmission in PARK.

21. Lock the parking brake.

22. Prime the oil pump using the procedure on page 95. Then stop

the engine and inspect for leaks.

23. Check the oil level. Add oil as needed to bring the level to the upper

mark on the dipstick.

24. Dispose of used filter and oil properly.

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MAINTENANCE

Engine Oil

Oil and Filter Change (500 EFI)

Oil Pump Priming

This priming procedure must be

performed whenever the oil hose

connection between the oil tank and

pump inlet has been disconnected.

Tank

(5 cm)

1. Clamp or pinch off the vent line

approximately 2" (5 cm) from

the oil tank, between the end of

the oil tank vent fitting and the

vent line's pressure relief slit.

Clamp

Pressure

Relief Slit

2. Start the engine. Allow it to idle

for 10-20 seconds.

3. Remove the vent line clamp. If the line is bled properly, you should

hear a rush of air, indicating that the line is properly primed and

ready for operation.

NOTE: If you do not hear air, the line has not bled. Repeat the priming

procedure.

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MAINTENANCE

Engine Oil

Oil and Filter Change (700/800 EFI)

CAUTION

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

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

Maintenance Chart beginning on page 85. Always change the oil filter

whenever changing oil.

1. Position the vehicle on a level surface.

2. Start the engine. Allow it to warm up at idle for two to three min-

utes.

3. Stop the engine.

Drain Plug Location

4. Clean the area around

the drain plug.

5. Place a drain pan

under the crankcase.

6. Remove the drain

plug. Allow the oil to

drain completely.

to front

7. Install a new sealing

washer on the drain

plug.

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

free of burrs, nicks or scratches.

8. Reinstall the drain plug. Torque to 20 ft. lbs. (27 Nm).

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MAINTENANCE

Engine Oil

Oil and Filter Change (700/800 EFI

9. Place shop towels beneath the oil

filter. Using an oil filter wrench

(available from your Polaris

dealer), turn the filter counter-

clockwise to remove it.

10. Using a clean dry cloth, clean the

filter sealing surface on the

crankcase.

11. Lubricate the o-ring on the new filter with a film of fresh engine oil.

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

12. Install the new filter and rotate it clockwise by hand until the filter

gasket contacts the sealing surface, then turn it an additional 1/2

turn.

13. Remove the dipstick.

14. Add two quarts (1.9 l) of recommended oil.

15. Place the transmission in PARK.

16. Lock the parking brake.

17. Start the engine. Allow it to idle for one to two minutes.

18. Stop the engine.

19. Check for leaks.

20. Check the oil level. Add oil as needed to bring the level to the upper

mark on the dipstick.

21. Dispose of used filter and oil properly.

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MAINTENANCE

Transmission Oil

Always check and change the transmission oil at the intervals outlined

in the Periodic Maintenance Chart beginning on page 85. Maintain the

oil level at the bottom of the fill plug hole threads. We recommend the

use of Polaris Premium AGL Synthetic Gearcase Lubricant. See page

143 for the part numbers of Polaris products.

The fill plug is located on the left side of the ATV, under the rear fender,

behind the wheel.

The drain plug is located on the right side of the gearcase, on the right

side of the ATV, behind the wheel well.

Fill Plug

Drain Plug

Transmission Oil Level

1. Position the vehicle on a level

Fill Plug

surface.

2. Remove the fill plug.

3. Check the oil level. Add the

recommended oil as needed.

4. Reinstall the fill plug. Torque

to 20-25 ft. lbs. (27-34 Nm).

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MAINTENANCE

Transmission Oil

Transmission Oil Change

1. Remove the fill plug.

2. Place a drain pan under the

gearcase.

3. Remove the drain plug. Allow

the oil to drain completely.

4. Clean and reinstall the drain

plug. Torque to 20-25 ft. lbs.

(27-34 Nm).

Drain

Plug

5. Add 32 oz. (948 ml) of the

recommended oil.

6. Reinstall the fill plug. Torque to 20-25 ft. lbs. (27-34 Nm).

7. Check for leaks. Dispose of used oil properly.

Front Gearcase (Demand Drive) Fluid

Always check and change the demand drive fluid at the intervals out-

lined in the Periodic Maintenance Chart beginning on page 85. We rec-

ommend the use of Demand Drive LT Premium Fluid. Use of other

fluids may result in improper operation of components. See page 143 for

the part numbers of Polaris products.

Maintain the fluid level at

the bottom of the fill hole

threads. See below for

capacity.

Fill

Plug

The fill plug is located on

the right side of the

demand drive unit. The

drain plug is located on the

bottom right side of the

unit.

Drain Plug

Fill Level

Demand Drive Capacities

Demand Drive with ADC

9.3 oz. (275 ml)

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MAINTENANCE

Front Gearcase (Demand Drive) Fluid

Fluid Level

1. Position the vehicle on a level surface.

2. Remove the fill plug. Check the fluid level.

3. Add the recommended demand drive fluid as needed to bring the

level to the bottom of the fill hole threads.

4. Reinstall the fill plug. Torque to 8-10 ft. lbs. (11-14 Nm).

Fluid Change

1. Position the vehicle on a level surface.

2. Remove the fill plug.

3. Place a drain pan under the demand drive unit.

4. Remove the drain plug. Allow the fluid to drain completely.

5. Clean and reinstall the drain plug. Torque to 11 ft. lbs. (15 Nm).

6. Add the recommended fluid. See page 99 for capacity. Maintain the

fluid level at the bottom of the fill hole threads.

7. Reinstall the fill plug. Torque to 8-10 ft. lbs. (11-14 Nm).

8. Check for leaks.

9. Dispose of used fluid properly.

Active Descent Control (ADC) Fluid

Two fluid levels must be maintained on your vehicle, the demand drive

fluid and the ADC fluid. See page 99 for demand drive fluid mainte-

nance.

Check and change the ADC fluid level at the intervals outlined in the

Periodic Maintenance Chart beginning on page 85. Maintain the fluid

level between the minimum and maximum marks on the reservoir. We

recommend the use of Polaris ADC Fluid. See page 143 for the part

numbers of Polaris products.

NOTE: Do not use brake fluid. Brake fluid will damage rubber components in

the hydraulic system.

100

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MAINTENANCE

Active Descent Control (ADC) Fluid

Fluid Level

1. Open the front box cover and pull open the

access door.

500 EFI

2. View the fluid level in the reservoir. If the

level is below the minimum mark, remove

the cap and add the recommended fluid.

3. Reinstall the cap securely. Secure the

access door and box cover.

Fluid Change

1. Position the vehicle on a level surface.

Before performing the fluid change, allow

the vehicle to sit for at least 30 minutes.

ADC Fluid Reservoir

700/800 EFI

2. Thoroughly clean the areas around and on

the ADC reservoir and bleeder valves (one

on each side of the differential).

3. Remove the reservoir cap and diaphragm

assembly. Use a shop towel or suction tool

to remove debris from the fluid and reser-

voir.

NOTE: Debris in the reservoir may result in inadequate bleeding and reduced

performance of the system.

4. Fill the reservoir to the maximum line with fresh ADC fluid.

5. Remove the protective caps from the bleeder valves.

6. Slowly loosen one of the valves (turn counter-clockwise) and allow

fluid and trapped air to flow from the fitting. Close the valve when

clean fluid begins to flow. Repeat this step for the remaining valve.

IMPORTANT: Close the bleeder valves before the reservoir fluid level drops

below the minimum fill line. Adding fluid to an empty reservoir will result in

trapped air. If the level drops below the minimum line, add fluid to the maximum

line and repeat step 6 before proceeding.

7. Torque the valves to 80 in. lbs. (9 Nm). Reinstall the valve caps.

8. Add fresh ADC fluid to the reservoir until the level is between the

minimum and maximum marks. Make sure the reservoir is free of

debris.

9. Reinstall the cap securely. Clean up any drips or spills.

101

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MAINTENANCE

Cooling System

The engine coolant level is controlled, or maintained, by the recovery

system. The recovery system components are the recovery bottle, the

radiator filler neck, the radiator pressure cap and the connecting hose.

As coolant operating temperature increases, the expanding (heated)

excess coolant is forced out of the engine, past the pressure cap, and into

the recovery bottle. As engine coolant temperature decreases the con-

tracting (cooled) coolant is drawn back up from the bottle, past the pres-

sure cap, and into the radiator.

NOTE: Some coolant level drop on new vehicles is normal as the system is

purging itself of trapped air. Check the coolant level and maintain as

recommended by adding coolant to the recovery bottle.

Polaris recommends the use of Polaris Premium 60/40 anti-freeze/cool-

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

coolant and distilled water. Polaris Premium 60/40 is already premixed

and ready to use. Do not dilute with water. See page 143 for the part

numbers of Polaris products.

NOTE: Always follow the manufacturer's mixing recommendations for the

freeze protection required in your area.

Recovery Bottle Coolant

The recovery bottle is located on

the left side of the vehicle.

1. Remove the left side panel.

See page 106.

2. Maintain the coolant level

between the minimum and

maximum marks on the bot-

tle (when the fluid is cool).

3. Add coolant as needed.

Recovery

Bottle

102

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MAINTENANCE

Cooling System

Radiator Coolant

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

Polaris recommends that you drain the system completely every two

years and add a fresh mixture of antifreeze and water.

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

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

in the radiator. Add coolant as needed.

WARNING

Escaping steam can cause severe burns. Never remove the pressure cap

while the engine is warm or hot. Always allow the engine to cool before

removing the pressure cap.

1. Open the front box cover and

pull open the access door.

2. Remove the pressure cap.

3. Using a funnel, slowly add

coolant through the radiator

filler neck.

4. Reinstall the pressure cap.

5. Secure the access door.

6. Secure the box cover.

NOTE: Use of a non-standard

Radiator Cap

pressure cap will not allow

the recovery system to

function properly. Contact

your dealer for the correct

replacement part.

103

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MAINTENANCE

Brakes

Hand Brake

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

the single brake lever toward the handlebar. These brakes are self-

adjusting.

Under normal operation, the diaphragm extends into the reservoir as

fluid level drops. If the fluid level is low and the diaphragm is not

extended, a leak is likely and the diaphragm should be replaced. To

ensure proper diaphragm operation, always fill the reservoir as needed

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

WARNING

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

could result in serious injury or death. Maintain brake fluid at the

recommended level. Do not overfill.

The following checks are recommended to keep the brake system in

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

under normal operation.

1. Always keep brake fluid at an adequate

level. See page 42.

2. Check the brake system for fluid leaks.

3. Check the brakes for excessive travel or

spongy feel.

4. Check the friction pads for wear, damage

and looseness. Replace brake pads when

they are worn to 3/64" (1 mm).

3/64" (1 mm)

5. Check the security and surface condition

of the disc.

Auxiliary Foot Brake

The hydraulic auxiliary brake system requires no adjustment. Check the

brake fluid level frequently for the auxiliary brake system. See page 44.

104

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MAINTENANCE

Toe Alignment

WARNING

Severe injury or death can result from improper toe alignment and

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

should be performed by an authorized Polaris dealer.

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

The recommended toe alignment is 1/8" to 1/4" (3-6 mm) toe out.

1. Position the vehicle on a

level surface.

2. Place the handlebars in a

straight-ahead position.

Stand

String

3. Tie a length of string

between two stands as

shown in the illustration.

Position the stands so

that the string is flush

with the side of the rear

tire.

NOTE: If available, you may

use a long straight-

edge instead of string.

4. Measure the distance

from the string to the

rim at the front (1) and

rear (2) of the front rim.

The rear measurement should be 1/16"-1/8" (2-3 mm) more than the

front measurement on each side of the vehicle to obtain the

recommended 1/8" to 1/4" (3-6 mm) toe out alignment.

5. Repeat the measurement procedure on the other side of the vehicle.

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

105

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MAINTENANCE

Steering Assembly

The steering assembly of the ATV should be checked periodically for

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

dealer for service before operating the vehicle.

Side Panel Removal

1. Remove the seat.

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

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

grommet. Pull the panel downward and rearward to remove it.

3. When reinstalling side panels, align the fasteners and press firmly to

secure them.

Step 1

Step 2

Step 3

Footwell Removal

1. Remove the six screws on

the bottom of the footwell.

Screws

2. Use a flat screwdriver or

sidecutters to remove the

plastic rivets securing the

footwell to the fenders.

3. Remove the footwell.

Rivets

106

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MAINTENANCE

Tires

Refer to the specifications section beginning on page 144 for recom-

mended tire type, size and pressure.

WARNING

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

tires or improperly installed tires will affect vehicle handling and could cause

an accident resulting in serious injury or death.

Maintain proper tire pressure as described on the decal on your ATV and in

the owner's manual.

Always use original equipment size and type when replacing tires.

Make sure the wheels are installed properly.

Always replace tires when the tread depth measures 1/8" (3 mm) or less.

Tire Tread Depth

Always replace tires

when tread depth is

worn to 1/8" (3 mm)

or less.

1/8" (3 mm)

Front Wheel Hub Tightening

Front wheel bearing tightness and spindle nut retention are critical com-

ponent operations. All service must be performed by your authorized

Polaris dealer.

Wheel Removal

1. Stop the engine.

2. Place the transmission in PARK.

3. Lock the parking brake.

4. Loosen the wheel nuts slightly.

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

footrest frame.

6. Remove the wheel nuts.

7. Remove the wheel.

107

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MAINTENANCE

Tires

Wheel Installation

WARNING

Improperly installed wheels can adversely affect tire wear and vehicle

handling, which can result in serious injury or death. Always ensure that all

nuts are torqued to specification. Do not service axle nuts that have a cotter

pin installed. See your Polaris dealer.

1. Place the transmission in PARK.

2. Lock the parking brake.

3. Place the wheel on the hub with the valve stem toward the outside

and rotation arrows on the tire pointing toward forward rotation.

4. Install the wheel nuts and finger-tighten them.

5. Lower the vehicle to the ground.

6. Torque the wheel nuts to specification.

90 ft. lbs.

(122 Nm)

27 ft. lbs.

(37 Nm)

Cast Aluminum

Steel

Wheel Nut Torque Specifications

Check the wheel nut torques occasionally and when they've been loos-

ened for service.

Nut Type

Nut Torque

Lug Nut

90 ft. lbs. (122 Nm)

27 ft. lbs. (37 Nm)

2-Piece Flange Nut

108

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MAINTENANCE

Pre-Filter

Air Filter

1. Remove the seat.

Main Filter

2. Release the air box cover clips,

and remove the air box cover.

3. Loosen the clamp and remove the

filter.

4. Remove the fabric type pre-filter

from the main filter. Wash the pre-

filter in soapy water, then rinse

and let dry.

5. Reinstall the pre-filter over the

main filter.

NOTE: Install a new main filter if

needed.

6. Reinstall the filter into the air box

and tighten the clamp. Do not over-tighten the clamp, as filter dam-

age could occur.

7. Reinstall the air box cover and the seat.

109

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MAINTENANCE

Breather Filter/Hose (500 EFI)

The breather filter is on

the hose that runs

between the engine and

air box.

1. Remove the left side

panel. See page 106.

2. Remove the hose

clamps from the fil-

ter and pull the filter

out of the hoses.

Breather Filter

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

direction of the arrow to check for clogging. Replace a damaged or

clogged filter.

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

Replace as needed.

5. Reinstall the filter and hose clamps.

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

CAUTION

Operation of your vehicle without a breather filter can cause engine damage.

Always reinstall the breather filter after removing it for service.

110

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MAINTENANCE

Fuse Replacement

If the engine stops or will not start,

or if you experience other electrical

failures, a fuse may need replace-

ment.

NOTE: Spare fuses are provided in a

compartment on the top of the

access door.

1. Open the front box cover and

pull open the access door.

2. Remove the suspect fuse from

the fuse panel. If the fuse is

blown, install a new fuse with

the same amperage.

Fuses

3. Secure the access door.

4. Secure the box cover.

Fuse Panel

5or6 15 20 20

111

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MAINTENANCE

Lights

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

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

the life of the lamp.

WARNING

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

taillight lenses become dirty during normal operation. Wash the headlights

frequently to maintain lighting quality.

Hot components can cause serious burns to skin. Allow lamps to cool before

servicing.

Headlight Lamp Replacement

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

pod.

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

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

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

the speedometer.

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

connector, not on the wiring.

6. Turn the lamp counterclockwise to remove it.

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

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

8. Reassemble the pod.

112

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MAINTENANCE

Lights

High Beam Adjustment

The headlight beam can be adjusted slightly upward or downward. Use

the following procedure to make the adjustment.

25 ft.

(7.6 m)

2" (5 cm)

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

mately 25 ft. (7.6 m) from a wall. Place the transmission in PARK.

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

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

3. Start the engine.Turn the headlight switch to high beam.

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

headlight beam should be two inches (5 cm) below the mark on the

wall.

NOTE: Include rider weight on the seat when measuring.

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

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

either clockwise or counterclockwise.

Low Beam Adjustment

Phillips Screw

The low beam can be adjusted slightly

upward or downward.

1. Loosen the phillips screw located

at the rear of the headlamp.

2. Tilt the headlamp upward or

downward.

3. Tighten the screw.

113

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MAINTENANCE

Lights

Headlight Housing Replacement

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

pod.

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

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

the speedometer.

4. Unplug the headlamp from the wiring harness.

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

mounting tabs.

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

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

8. Carefully pull the assembly up

and out of the pod.

9. Reverse the steps to install the

new housing and reassemble

the pod.

NOTE: The distance from the head-

lamp parting line to the end of

the adjustment knob stop is 5

1/8" (13 cm).

5 1/8"

(13 cm)

10. Adjust the headlight aim by

turning the adjusting knob.

114

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MAINTENANCE

Lights

Lower Headlamp Replacement

1. Turn the back of the headlight

harness counterclockwise and

pull the harness assembly away

from the headlight assembly.

2. Remove the headlamp and install

the new headlamp.

3. Reinstall the harness assembly

into the headlight assembly.

Harness

4. Turn the headlight harness clock-

wise to secure the headlamp.

Taillight/Brakelight/Worklight (if equipped) Lamp

Replacement

1. Open the tailgate.

2. Remove the two screws near the

tailgate latch.

Screws

3. Grasp the entire taillight assembly

and pull it away from the vehicle.

4. Remove the harness connector

from the back of the light assem-

bly.

5. Turn the lamp counterclockwise to

remove it.

Lamp

6. Apply dielectric grease to the

socket and install the new lamp.

7. Reinstall the harness connector.

8. Test the light for proper operation.

9. Reinstall the taillight assembly.

10. Reinstall the two screws.

115

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MAINTENANCE

Spark Plugs

Spark Plug Recommendations

CAUTION

Using non-recommended spark plugs can result in serious engine damage.

Always use Polaris-recommended spark plugs.

Refer to the specifications section beginning on page 144 for the recom-

mended spark plug type and gap for your vehicle. Torque spark plugs to

specification.

Plug Condition

Torque Specification

New Spark Plug

9-11 ft. lbs. (12-15 Nm)

17-20 ft. lbs. (23-27 Nm)

Previously Installed Spark Plug

Spark Plug Inspection

Spark plug condition is indicative of engine operation. Check the spark

plug firing end condition after the engine has been warmed up and the

vehicle has been driven at higher speeds. Immediately check the spark

plug for correct color. See page 117.

WARNING

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

gloves when removing a spark plug for inspection.

1. Rotate the spark plug cap 1/4 turn and pull it off the spark plug.

2. Using the special wrench provided in the tool pouch, rotate the

spark plug counterclockwise to remove it.

3. Reverse the procedure for spark plug installation. Torque to specifi-

cation.

116

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MAINTENANCE

Spark Plugs

Spark Plug Inspection

Normal Spark Plug

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

combustion deposits. The electrodes are not burned or eroded. This indi-

cates the proper type and heat range for the engine and the service.

NOTE: The tip should not be flaky and white. A white insulator tip indicates

overheating, caused by use of an improper spark plug or incorrect

fuel.

Wet Fouled Spark Plug

The wet fouled insulator tip is black. A damp oil film covers the firing

end. There may be a carbon layer over the entire nose. Generally, the

electrodes are not worn. General causes of fouling are excessive oil, use

of non-recommended oil or incorrect throttle body adjustments.

Recoil Housing (500 EFI)

Always drain the recoil housing after operating the vehicle in wet condi-

tions. Drain the housing before storing the vehicle. Make sure the hous-

ing is completely dry before reinstalling the drain plug.

1. Stop the engine.

2. Place the transmission in gear.

3. Lock the parking brake.

4. Remove the drain screw on the

bottom of the recoil housing.

5. Reinstall the drain screw.

NOTE: Do not open the crankcase drain

unless the engine has ingested

water. On 4-cycle engines, some

engine oil will be lost if the crank-

case drain is opened.

117

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MAINTENANCE

Vehicle Immersion

CAUTION

If your vehicle becomes immersed, major engine damage can result if the

machine is not thoroughly inspected. Take the vehicle to your dealer before

starting the engine.

1. If it's impossible to take your ATV to a dealer before starting it, fol-

low the steps outlined below.

2. Move the ATV to dry land or at the very least, to water below the

footrests.

3. Check the air box. If water is present, dry the air box and replace the

filter with a new filter.

4. Remove the spark plug.

5. Turn the engine over several times using the electric start.

6. Dry the spark plug. Reinstall the plug or install a new plug.

7. Attempt to start the engine. If necessary, repeat the drying proce-

dure.

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

you succeed in starting it or not.

9. If water has been ingested into the PVT, follow the procedure on

page 122 for drying out the PVT.

118

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MAINTENANCE

Spark Arrestor

WARNING

Failure to heed the following warnings while servicing the spark arrestor

could result in serious injury or death.

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. Exhaust contains

poisonous carbon monoxide gas. Never go under the vehicle while it's

inclined.

Use the following procedure to periodically purge accumulated carbon

from the exhaust pipe/muffler.

1. Remove the arrestor clean-out

plug from the bottom of the

muffler.

Exhaust

Outlet

2. Place the transmission in

PARK.

3. Start the engine.

4. Quickly squeeze and release

the throttle lever several times

to purge carbon from the system.

Clean-Out Plug

5. If carbon comes out of the exhaust, cover or plug the exhaust outlet.

Wear protective gloves.

6. Lightly tap on the exhaust pipe with a rubber mallet while repeating

step 4.

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

the vehicle one foot (30 cm) higher than the front. Block the wheels.

8. Place the transmission in PARK. Lock the parking brake. Repeat

steps 4 to 6 until no more particles are expelled.

9. Stop the engine. Allow the arrestor to cool.

10. Reinstall the arrestor plug and remove the exhaust outlet cover or

plug.

119

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MAINTENANCE

PVT System

WARNING

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

injury or death.

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

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

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

balance, creating vibration and additional loads on components.

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

clutch components. Extensive engineering and testing has been conducted

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

following responsibilities to make sure this system remains safe:

• Always follow all recommended maintenance procedures. See your dealer

as outlined in the owner's manual.

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

it in any other product.

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

120

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MAINTENANCE

PVT System

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

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

force exerted on the movable drive sheave by the flyweights also

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

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

trifugal force decreases, reducing the amount of belt pinch.

On Polaris ATVs, the approximate gear ratio difference between high

and low range is 1:2.25. This difference in gearing affects the operation

of the PVT, especially at speeds less than 7 MPH (11 km/h), due to the

system's dependence on engine speed.

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

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

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

range at 3 MPH (5 km/h), the engine would be running at only 1500

RPM. Whenever operating this close to the engagement speed, the

engine may be running at a speed too low to provide the pinch needed to

prevent belt slip. Belt slip is responsible for creating the excessive heat

that destroys belts, wears clutch components and causes outer clutch

covers to fail.

By switching to low range while operating at low ground speeds, the air

temperature in the clutch cover is reduced by almost 160 degrees.

Reducing the temperature inside the clutch cover extends the life of the

PVT components (belt, cover, etc.).

121

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MAINTENANCE

PVT System

When To Use Low Range and High Range

Condition

Range to Use

Operating at speeds less than 7 MPH (11 km/h)

Towing heavy loads

Low

High

Operating in rough terrain (swamps, mountains, etc.)

Operating at speeds greater than 7 MPH (11 km/h)

PVT Drying

There may be some instances when water is accidently ingested into the

PVT system. Use the following instructions to dry it out before operat-

ing.

1. Position the vehicle on a level surface.

2. Remove the drain plug. Allow the water to drain completely. Rein-

stall the drain plug.

3. Start the engine. Place the transmission in PARK.

4. Apply varying throttle for 10-15 seconds to expel the moisture and

air-dry the belt and clutches.

NOTE: Do not hold the throttle wide open for more than 10 seconds.

5. Allow the engine RPM to settle to idle speed, then shift the trans-

mission to the lowest available range.

6. Test for belt slippage. If the belt slips, repeat the process.

7. Take the vehicle to your dealer for service as soon as possible.

122

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MAINTENANCE

Battery

Your ATV may have either a sealed battery, which requires little mainte-

nance, or a conventional battery. A sealed battery can be identified by its

flat covers on the top of the battery. A conventional battery has six filler

caps on the top of the battery.

Conventional Battery

Always keep battery terminals and connections free of corrosion. If

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

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

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

nals with dielectric grease or petroleum jelly. Be careful not to allow

cleaning solution or tap water into a conventional battery.

WARNING

Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can

result from contact with skin, eyes or clothing.

Antidote:

External: Flush with water.

Internal: Drink large quantities of water or milk. Follow with milk of magnesia,

beaten egg, or vegetable oil. Call physician immediately.

Eyes: Flush with water for 15 minutes and get prompt medical attention.

Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc.

away. Ventilate when charging or using in an enclosed space. Always shield

eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN.

123

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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.

Battery Removal

1. Loosen the battery hold-down bolt.

2. Remove the battery cover.

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

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

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

6. Lift the battery out of the ATV. Be careful not to tip a conventional

battery sideways, which could spill electrolyte.

CAUTION

If electrolyte spills, immediately wash it off with a solution of one tablespoon

baking soda and one cup water to prevent damage to the vehicle.

124

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MAINTENANCE

Battery

Battery Installation

Using a new battery that has not been fully charged can damage the bat-

tery and result in a shorter life. It can also hinder vehicle performance.

Follow the battery charging instructions on page 127 before installing

the battery.

1. Ensure that the battery is fully charged.

2. Place the battery in the battery holder.

3. With conventional batteries, install the battery vent tube (sealed bat-

teries do not have a vent tube).

NOTE: The vent tube must be free of obstructions and securely installed.

Route the tube away from the frame and vehicle body to prevent con-

tact with electrolyte.

WARNING

Battery gases could accumulate in an improperly installed vent tube and

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

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

recommended.

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

or petroleum jelly.

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

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

7. Install the battery cover.

8. Tighten the battery hold-down bolt.

9. Verify that cables are properly routed.

NOTE: Cables should be safely tucked away at the front and rear of the bat-

tery.

125

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MAINTENANCE

Battery

Battery Storage

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

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

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

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

NOTE: Power plug leads may need to be bent down so that the battery cover

can be installed.

NOTE: Battery charge can be maintained by using a Polaris Battery Tender

charger or by charging about once a month to make up for normal self-

discharge. Battery Tender can be left connected during the storage

period, and will automatically charge the battery if the voltage drops

below a pre-determined point. See page 143 for the part numbers of

Polaris products.

Battery Fluid (Conventional Battery)

A poorly maintained battery will

Upper

Mark

Lower

Mark

deteriorate rapidly. Check the battery

fluid level often. Maintain the fluid

level between the upper and lower

level marks.

Add only distilled water. Tap water

contains minerals that are harmful to

a battery.

126

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MAINTENANCE

Battery

Battery Charging (Conventional Battery)

1. Remove the battery from the vehicle to prevent damage from leak-

ing or spilled electrolyte during charging. See page 124.

2. Charge the battery with a charging output no larger than 1/10 of the

battery’s amp/hr rating. Charge as needed to raise the specific grav-

ity to 1.270 or greater.

3. Reinstall the battery. See page 125. Make sure the positive terminal

is toward the front of the vehicle.

Battery Charging (Sealed Battery)

The following battery charging instructions apply only to the installa-

tion of a sealed battery. Read all instructions before proceeding with the

installation of this battery.

The sealed battery is already filled with electrolyte and has been sealed

and fully charged at the factory. Never pry the sealing strip off or add

any other fluid to this battery.

The single most important thing about maintaining a sealed battery is to

keep it fully charged. Since the battery is sealed and the sealing strip

cannot be removed, you must use a voltmeter or multimeter to measure

DC voltage.

WARNING

An overheated battery may explode, causing severe injury or death. Always

watch charging times carefully. Stop charging if the battery becomes very

warm to the touch. Allow it to cool before resuming charging.

For a refresh charge, follow all instructions carefully.

1. Check the battery voltage with a voltmeter or multimeter. A fully

charged battery will register 12.8 V or higher.

2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps

or less until battery voltage is 12.8 or greater.

NOTE: When using an automatic charger, refer to the charger manufacturer's

instructions for recharging. When using a constant current charger,

use the guidelines on the next page for recharging.

127

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MAINTENANCE

Battery

Battery Charging (Sealed Battery)

NOTE: Always verify battery condition before and 1-2 hours after the end of

charging.

Charge Time

State of

Charge

(Using constant current

Voltage

Action

charger @ standard amps

specified on top of battery)

100%

12.8-13.0 volts

None, check at 3

mos. from date of

manufacture

None required

75%-100%

12.5-12.8 volts

May need slight

charge, if no

3-6 hours

charge given,

check in 3 months

50%-75%

25%-50%

12.0-12.5 volts

11.5-12.0 volts

Needs charge

5-11 hours

At least 13 hours,

verify state of charge

0%-25%

11.5 volts or less Needs charge with

desulfating charger

At least 20 hours

128

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MAINTENANCE

Cleaning and Storage

Washing the Vehicle

Keeping your Polaris vehicle clean will not only improve its appearance

but it can also extend the life of various components.

CAUTION

High water pressure may damage components. Polaris recommends

washing the vehicle by hand or with a garden hose, using mild soap.

Certain products, including insect repellents and chemicals, will damage

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

The best and safest way to clean your Polaris vehicle is with a garden

hose and a pail of mild soap and water.

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

and the lower parts last.

2. Rinse with clean water frequently.

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

Washing Tips

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

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

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

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

reused cloths and pads may contain dirt particles that will scratch the

finish.

129

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MAINTENANCE

Cleaning and Storage

Washing the Vehicle

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

exercise extreme caution. The water may damage components and could

remove paint and decals. Avoid directing the water stream at the follow-

ing items:

• Wheel bearings

• Radiator

• Transmission seals

• Brakes

• Cab and body panels

• Labels and decals

• Electrical components and wiring

NOTE: If warning and safety labels are damaged, contact your Polaris dealer

for free replacement.

Grease all zerk fittings immediately after washing. Allow the engine to

run for a while to evaporate any water that may have entered the engine

or exhaust system.

Polishing the Vehicle

Polaris recommends the use of common household aerosol furniture

polish for polishing the finish on your Polaris vehicle. Follow the

instructions on the container.

Polishing Tips

• Avoid the use of automotive products, some of which can scratch the

finish of your vehicle.

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

reused cloths and pads may contain dirt particles that will scratch the

finish.

130

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MAINTENANCE

Cleaning and Storage

Chrome Wheel Care (if equipped)

Proper maintenance will protect chrome wheels from corrosion, pre-

serve wheel life and ensure a "like new" appearance for many years.

NOTE: Chrome wheels exposed to road salt (or salt in the air in coastal areas)

are more susceptible to corrosion if not properly cleaned. Clean

chrome wheels more often if they're exposed to salt or other corrosive

elements.

1. Wash chrome wheels frequently. Use a mild detergent. Never use

abrasive cleaners on plated or painted surfaces.

2. Rinse well with clear water. Soap, detergents, salt, dirt, mud and

other elements can cause corrosion.

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

grade chrome polish.

4. Routinely and liberally apply a weather resistant wax to each pol-

ished chrome wheel. Choose a product suitable for chrome finishes.

Read and follow the product labels and instructions.

Removing Corrosion

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

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

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

lined above.

131

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MAINTENANCE

Cleaning and Storage

Storage Tips

CAUTION

Starting the engine during the storage period will disturb the protective film

created by fogging and damage could occur. Never start the engine during

the storage period.

Clean the Exterior

Make any necessary repairs and clean the vehicle as recommended. See

page 129.

Stabilize the Fuel

1. Fill the fuel tank.

2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer.

Follow the instructions on the container for the recommended

amount.

NOTE: Carbon Clean removes water from fuel systems, stabilizes fuel and

removes carbon deposits from pistons, rings, valves and exhaust sys-

tems.

3. Allow the engine to run for 15-20 minutes to allow the stabilizer to

disperse through the entire fuel delivery system.

Oil and Filter

Change the oil and filter. See page 93.

Air Filter / Air Box

1. Inspect and clean (or replace) the pre-cleaner and air filter. See page

109.

2. Clean the air box.

3. Drain the sediment tube.

4. Clean or replace the breather filter (if equipped). See page 110.

Recoil Housing (500 EFI)

Drain the recoil housing. See page 117.

132

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MAINTENANCE

Cleaning and Storage

Storage Tips

Fluid Levels

Inspect the fluid levels. Add or change fluids as recommended in the

Periodic Maintenance Chart beginning on page 85.

• Demand drive unit (front gearcase)

• ADC fluid (ADC models) (change every two years)

• Rear gearcase (if equipped)

• Transmission

• Brake fluid (change every two years and any time the fluid looks dark

or contaminated)

• Coolant (test strength/fill)

Fog the Engine

1. Treat the fuel system with Polaris Carbon Clean. Follow the instruc-

tions on the container. Start the engine. Allow it to idle for several

minutes so the Carbon Clean reaches the injectors. Stop the engine.

2. Remove the spark plug and add 2-3 tablespoons of engine oil. To

access the plug hole, use a section of clear 1/4" hose and a small

plastic squeeze bottle filled with the pre-measured amount of oil.

NOTE: Do this carefully! If you miss the plug hole, oil will drain from the spark

plug cavity into the hole at the front of the cylinder head, and appear to

be an oil leak.

3. Reinstall the spark plug. Torque to specification.

4. Apply dielectric grease to the inside of each spark plug cap and rein-

stall the caps onto the plugs.

5. Turn the engine over several times. Oil will be forced in and around

the piston rings and ring lands, coating the cylinder with a protec-

tive film of fresh oil.

6. If Polaris fuel system additive is not used, the fuel tank, fuel lines,

and injectors should be completely drained of gasoline.

133

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MAINTENANCE

Cleaning and Storage

Storage Tips

Inspect and Lubricate

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

in the Periodic Maintenance Chart beginning on page 85.

Battery Storage

See pages 126-127 for storage and charging procedures.

Storage Area/Covers

Set the tire pressure and safely support the ATV with the tires slightly

off the ground. Be sure the storage area is well ventilated. Cover the

vehicle with a genuine Polaris cover.

NOTE: Do not use plastic or coated materials. They do not allow enough ven-

tilation to prevent condensation, and may promote corrosion and oxi-

dation.

Accessories

Auxiliary power outlets provide 12-volt power for operating accesso-

ries. Accessory outlets are available for all models. Polaris also has a

wide range of additional accessories available for your ATV. Always

install accessories that are approved for ATV use. Please see your

Polaris dealer.

134

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MAINTENANCE

Transporting the ATV

Follow these procedures when

transporting the vehicle.

1. Stop the engine.

2. Place the transmission in

PARK.

3. Lock the parking brake.

4. Always secure the seat in the

1-up position to prevent loss

during transporting.

5. Secure the fuel cap and oil

cap.

6. Always tie the frame of the

ATV to the transporting unit

securely with suitable straps

or rope. Do not attach tie

straps to the front A-arm bolt

pockets.

7. Remove the key to prevent

loss during transporting.

135

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ADJUSTMENTS

Camber and Caster

The camber and caster are non-adjust-

able.

Rear Spring

The rear shock absorber spring is

adjusted by rotating the adjuster either

clockwise or counterclockwise to

increase or decrease spring tension.

NOTE: Accessory springs are available

through your Polaris dealer.

Adjuster

136

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ADJUSTMENTS

Handlebars

The handlebars can be adjusted for rider preference.

WARNING

Improper adjustment of the handlebars or incorrect torquing of the adjuster

block tightening bolts can cause limited steering or loosening of the

handlebars, resulting in loss of control and possible serious personal injury or

death. Follow the adjustment procedures exactly, or see your Polaris dealer

for service.

1. Remove the upper headlight

pod.

2. Loosen the four handlebar

bolts.

3. Adjust the handlebar to the

desired height.

NOTE: Be sure the handlebars do

not contact the gas tank or

any other part of the machine

when turned fully to the left or

right.

4. Torque the front two bolts to

Handlebar

Bolts

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

torque the rear two bolts. A

gap of up to 1/8" (3 mm) will

remain at the rear of the clamp

blocks.

137

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ADJUSTMENTS

Throttle Body/Idle RPM

Idle RPM is preset by the manufacturer. If the engine idle speed is not

satisfactory, please see your Polaris dealer for adjustment.

Throttle Cable Freeplay

Adjust throttle cable freeplay at the handlebar.

1. Locate the throttle cable

adjuster at the handlebar.

2. Squeeze the end of the rub-

ber boot and slide it far

enough to expose the end of

the inline cable adjuster.

3. Loosen the adjuster lock nut.

4. Rotate the boot to turn the

adjuster until 1/16" to 1/8"

(1.5-3 mm) of freeplay is

achieved at the thumb lever.

NOTE: While adjusting freeplay,

be sure to flip the throttle

lever back and forth.

Boot

5. Tighten the lock nut.

6. Squeeze the end of the rub-

ber boot and slide it over the

cable adjuster to its original

position.

Lock Nut

Adjuster

138

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TROUBLESHOOTING

Drive Belt Wear/Burn

Possible Cause

Solution

Driving onto a pickup or Use low range during loading.

tall trailer in high range

Starting out going up a

steep incline

Use low range or turn around using the K-turn (see page

76).

Driving at low RPM or

Drive at a higher speed or use low range more frequently.

ground speed (3-7 MPH) See page 122.

Insufficient warm-up at

low ambient tempera-

tures

Warm the engine at least 5 minutes. With the transmission

in neutral, advance the throttle to about 1/8 throttle in

short bursts, 5 to 7 times. The belt will become more flex-

ible and prevent belt burning.

Slow/easy clutch engage- Use the throttle quickly and effectively.

ment

Towing/pushing at low

RPM/low ground speed

Use low range only.

Utility use/plowing

Use low range only.

Stuck in mud or snow

Shift the transmission to low range and carefully use fast,

aggressive throttle application to engage clutch.

WARNING: Excessive throttle may cause loss of control

and vehicle overturn.

Climbing over large

objects from a stopped

position

Shift the transmission to low range and carefully use fast,

brief, aggressive throttle application to engage clutch.

WARNING: Excessive throttle may cause loss of control

and vehicle overturn.

Belt slippage from water Dry out the PVT. See page 122. Inspect clutch seals for

or snow ingestion into the damage if repeated leaking occurs.

PVT system

Clutch malfunction

See your Polaris dealer.

Poor engine performance Check for fouled plugs or foreign material in gas tank or

fuel lines. See your dealer.

Slippage from failure to

warm up belt

Always warm up the belt by operating below 30 mph for

one mile (5 miles or more when temperature is below

freezing).

Wrong or missing belt

Improper break-in

Install the recommended belt.

Always break in a new belt and/or clutch. See page 61.

139

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TROUBLESHOOTING

Engine Doesn't Turn Over

Possible Cause

Solution

Low battery voltage

Recharge the battery to 12.8 VDC

Check all connections and tighten

Loose battery connections

Loose solenoid connections

Engine Turns Over, Fails to Start

Possible Cause

Solution

Out of fuel

Refuel, cycle key to ON position three

times for 5 seconds each, then start

Clogged fuel filter

Replace the filter

Water is present in fuel

Old or non-recommended fuel

Fouled or defective spark plug(s)

No spark to spark plug

Water or fuel in crankcase

Low battery voltage

Drain the fuel system and refuel

Replace with fresh recommended fuel

Inspect plugs and replace if necessary

Inspect plugs, verify stop switch is on

Immediately see your Polaris dealer

Recharge the battery to 12.8 VDC

See your dealer

Mechanical failure

Engine Backfires

Possible Cause

Solution

Weak spark from spark plug

Inspect, clean and/or replace spark

plug(s)

Incorrect spark plug gap or heat range

Old or non-recommended fuel

Incorrectly installed spark plug wires

Incorrect ignition timing

Set gap to specs or replace plugs

Replace with fresh recommended fuel

See your dealer

Mechanical failure

See your dealer

Loose ignition connections

Water present in fuel

Check all connections and tighten

Replace with fresh recommended fuel

140

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TROUBLESHOOTING

Engine Pings or Knocks

Possible Cause

Solution

Poor quality or low octane fuel

Incorrect ignition timing

Replace with recommended fuel

See your dealer

Incorrect spark plug gap or heat range

Set gap to specs or replace plugs

Engine Runs Irregularly, Stalls or Misfires

Possible Cause

Solution

Fouled or defective spark plug(s)

Inspect, clean and/or replace spark

plug(s)

Worn or defective spark plug wires

Incorrect spark plug gap or heat range

Loose ignition connections

Water present in fuel

See your dealer

Set gap to specs or replace plugs

Check all connections and tighten

Replace with new fuel

Recharge battery to 12.8 VDC

Inspect and replace

Low battery voltage

Kinked or plugged fuel tank vent line

Incorrect fuel

Replace with recommended fuel

Inspect and clean or replace

See your dealer

Clogged air filter

Reverse speed limiter malfunction

Electronic throttle control malfunction

Other mechanical failure

See your dealer

Possible Lean Fuel Cause

Solution

Low or contaminated fuel

Kinked or plugged fuel tank vent line

Low octane fuel

Add or change fuel, clean the fuel system

Inspect and replace

Replace with recommended fuel

Replace filter

Clogged fuel filter

Incorrect fuel

Replace with recommended fuel

Possible Rich Fuel Cause

Solution

Fuel is very high octane

Replace with lower octane fuel

Stopping/starting without adequate

warm-up

Allow engine to warm up before operat-

ing and/or stopping

Incorrect fuel

Replace with recommended fuel

Inspect and clean or replace

Clogged air filter

141

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TROUBLESHOOTING

Engine Stops or Loses Power

Possible Cause

Solution

Out of fuel

Refuel, cycle key to ON position three

times for 5 seconds each, then start

Kinked or plugged fuel vent line

Water is present in fuel

Inspect and replace

Replace with new fuel

Fouled or defective spark plug(s)

Inspect, clean and/or replace spark

plug(s)

Worn or defective spark plug wires

Incorrect spark plug gap or heat range

Loose ignition connections

Low battery voltage

See your dealer

Set gap to specs or replace plug

Check all connections and tighten

Recharge the battery to 12.8 VDC

Replace with fresh recommended fuel

Inspect and clean or replace

See your dealer

Incorrect fuel

Clogged air filter

Reverse speed limiter malfunction

Electronic throttle control malfunction

Other mechanical failure

Overheated engine

See your dealer

Clean radiator screen and core, clean

engine exterior, see your dealer

Engine Overheating

Possible Cause

Solution

Debris lodged in screen

Remove and clean the screen. Pull on the

top portion of the screen, then remove the

lower portion.

Plugged Radiator

Use a garden hose to flush any debris

from the radiator fins. NOTE: High pres-

sure washers can deform the radiator fins

and reduce cooling efficiency.

142

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POLARIS PRODUCTS

Part

Number

Description

Engine Lubricant

2870791

2876244

2876245

Fogging Oil (12 oz. Aerosol)

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

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

Gearcase / Transmission Lubricants

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

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

Active Descent Control (ADC) Fluid

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

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

Pump for Gallon (3.8 l) Jug

2873602

2873603

2876144

2871653

2872276

2870465

2876251

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

Coolant

2871323

2871534

60/40 Coolant (gal./3.8 l)

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

Grease / Specialized Lubricants

2871312

2871322

2871423

2871460

2871515

2871551

2871329

2872073

2872348

Grease Gun Kit, Premium All Season

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

Premium All Season Grease (14 oz./414 ml cartridge)

Starter Drive Grease

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

Premium U-Joint Lube (14 oz./414 ml cartridge)

Dielectric Grease (Nyogel^TM

)

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

Chain Lube, Aerosol (16 oz./473 ml)

Additives / Miscellaneous

Carbon Clean Plus

Fuel Stabilizer

DOT 4 Brake Fluid

2871326

2870652

2872189

2871956

2859044

Loctite^TM565 Thread Sealant

Polaris Battery Tender^TMCharger

143

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SPECIFICATIONS

Sportsman X2 500 EFI

Maximum Weight Capacity

705 lbs. (320 kg) (includes operator, passenger,

cargo, accessories)

Dry Weight

798 lbs. (362 kg) (base model)

Front Rack/Storage Box Capacity 90 lbs. (41 kg)

Rear Storage Box Capacity 400 lbs. (181 kg)

Receiver Hitch Tongue Capacity 120 lbs. (55 kg) (Rear box capacity and tongue

weight not to exceed 400 lbs./181 kg)

Receiver Hitch Towing Capacity 1225 lbs. (557 kg) on level ground

Overall Length

93 in. (236 cm)

Overall Width

48 in. (122 cm)

Overall Height

48 in. (122 cm)

Wheelbase

57 in. (145 cm)

Ground Clearance

Minimum Turning Radius

Fuel Capacity

11 in. (28 cm)

82 in. (208 cm) unloaded

6 gal. (22.7 l)

Engine Oil Capacity

Coolant Capacity

Demand Drive Fluid Capacity

Transmission Oil Capacity

Engine

2 qts. (1.9 l)

2.7 qts. (2.5 l)

9.3 oz. (275 ml)

32 oz. (948 ml)

EH50PLE

Displacement

499 cc

Bore x Stroke

92 x 75

Alternator Output

Compression Ratio

Fuel System

350 w

10.2:1

Electronic Fuel Injection

Electronic Ignition

10 +/- 1 BTDC @ idle

NGK BKR6E

Ignition System

Ignition Timing

Spark Plug

Spark Plug Gap

Lubrication System

Driving System Type

Front Suspension

Rear Suspension

.035+0.0/-0.004 in. (0.9+0.0/-0.1 mm)

Dry Sump

Automatic PVT (Polaris Variable Transmission)

MacPherson strut with 8.2" (21 cm) travel

Progressive rate with 8.75" (22 cm) travel

144

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SPECIFICATIONS

Sportsman X2 500 EFI

Transmission

Automatic EBS (Engine Braking System)

with E-Z Shift H/L/N/R/P

Gear Reduction, Low

Gear Reduction, Reverse

Gear Reduction, High

Drive Ratio, Front

Tires/Pressure, Front

Tires/Pressure, Rear

Brakes, Front

23.91:1

21.74:1

10.57:1

3.82:1

25x8-12 / 5 psi

25x11-12 / 5 psi

Single-Control Hydraulic Disc

Foot-Activated Hydraulic Disc

Hydraulic lock, all wheel

Brakes, Rear

Brake, Auxiliary

Brake, Parking

Headlight

1 Single Beam on Headlight Pod (50 watt)

2 Single Beam on Bumper (37.5 watt)

Taillights

8.26 watts

26.9 watts

LCD

Brake Light

Instrument Cluster

Clutching (EBS Models)

Altitude

Shift

Weight

Drive Clutch

Spring

Driven

Clutch

Spring

Helix*

Meters

(Feet)

0-1800

(0-6000)

10 WH

Blue/Green

Yellow

PN 3234451

EBS

PN 3234356

PN 5630710 PN 7041157

1800-3700

10 RH

Blue/Green

Yellow

PN 3234451

EBS

PN 3234356

(6000-12000) PN 5630709 PN 7041157

NOTE: *EBS models require no helix/spring adjustment

145

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SPECIFICATIONS

Sportsman X2 700 EFI

Maximum Weight Capacity

705 lbs. (320 kg) (includes operator, passenger,

cargo, accessories)

Dry Weight

830 lbs. (376.5 kg) (base model)

Front Rack/Storage Box Capacity 90 lbs. (41 kg)

Rear Storage Box Capacity 400 lbs. (181 kg)

Receiver Hitch Tongue Capacity 150 lbs. (68 kg) (Rear box capacity and tongue

weight not to exceed 400 lbs./181 kg)

Receiver Hitch Towing Capacity 1500 lbs. (680 kg) on level ground

Overall Length

93 in. (236 cm)

Overall Width

48 in. (122 cm)

Overall Height

48 in. (122 cm)

Wheelbase

57 in. (145 cm)

Ground Clearance

Minimum Turning Radius

Fuel Capacity

11 in. (28 cm)

82 in. (208 cm) unloaded

6 gal. (22.7 l)

Engine Oil Capacity

Coolant Capacity

Demand Drive Fluid Capacity

Transmission Oil Capacity

Engine

2 qts. (1.9 l)

3.4 qts. (3.2 l)

9.3 oz. (275 ml)

32 oz. (948 ml)

EH0680LE

Displacement

683 cc

Bore x Stroke

80 x 68

Alternator Output

Compression Ratio

Starting System

Fuel System

500 Watts @3000 RPM

9.40:1

Electric

Electronic Fuel Injection

ECU

Ignition System

Ignition Timing

Spark Plug

8 BTDC @ 2000 RPM

RC7YC

Spark Plug Gap

Lubrication System

Driving System Type

Front Suspension

Rear Suspension

.035 in. (0.9 mm)

Pressurized Wet Sump

Automatic PVT (Polaris Variable Transmission)

MacPherson strut with 8.2" (21 cm) travel

Progressive rate with 8.75" (22 cm) travel

146

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SPECIFICATIONS

Sportsman X2 700 EFI

Transmission

Automatic EBS (Engine Braking System)

with E-Z Shift H/L/N/R/P

Gear Reduction, Low

Gear Reduction, Reverse

Gear Reduction, High

Drive Ratio, Front

Tires/Pressure, Front

Tires/Pressure, Rear

Brakes, Front

23.91:1

21.74:1

8.28:1

3.82:1

25x8-12 / 5 psi

25x11-12 / 5 psi

Single-Control Hydraulic Disc

Foot-Activated Hydraulic Disc

Hydraulic lock, all wheel

Brakes, Rear

Brake, Auxiliary

Brake, Parking

Headlight

1 Single Beam on Headlight Pod (50 watt)

2 Single Beam on Bumper (37.5 watt)

Taillights

8.26 watts

26.9 watts

LCD

Brake Light

Instrument Cluster

Clutching (EBS Models)

Altitude

Shift

Weight

Drive Clutch

Spring

Driven

Clutch

Spring

Helix*

Meters

(Feet)

0-1800

21-70.5

66-56-33

BA500

(0-6000)

PN 5632106

Red/White

Red

PN 7043349 PN 3234452

EBS

1800-3700

(6000-12000)

21-68

PN 5632128

PN 3234604

NOTE: *EBS models require no helix/spring adjustment

147

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SPECIFICATIONS

Sportsman X2 800 EFI

Maximum Weight Capacity

705 lbs. (320 kg) (includes operator, passenger,

cargo, accessories)

Dry Weight

880 lbs. (399 kg) (base model)

Front Rack/Storage Box Capacity 90 lbs. (41 kg)

Rear Storage Box Capacity 400 lbs. (181 kg)

Receiver Hitch Tongue Capacity 150 lbs. (68 kg) (Rear box capacity and tongue

weight not to exceed 400 lbs./181 kg)

Receiver Hitch Towing Capacity 1500 lbs. (680 kg) on level ground

Overall Length

93 in. (236 cm)

Overall Width

48 in. (122 cm)

Overall Height

48 in. (122 cm)

Wheelbase

57 in. (145 cm)

Ground Clearance

Minimum Turning Radius

Fuel Capacity

11 in. (28 cm)

82 in. (208 cm) unloaded

6 gal. (22.7 l)

Engine Oil Capacity

Coolant Capacity

Demand Drive Fluid Capacity

Transmission Oil Capacity

Engine

2 qts. (1.9 l)

3.4 qts. (3.2 l)

9.3 oz. (275 ml)

32 oz. (948 ml)

EH0760LE

Displacement

760 cc

Bore x Stroke

80x76

Alternator Output

Compression Ratio

Fuel System

500 Watts @3000 RPM

10:1

Electronic Fuel Injection

Electronic Ignition

Variable - ECU controlled

RC7YC

Ignition System

Ignition Timing

Spark Plug

Spark Plug Gap

Lubrication System

Driving System Type

Front Suspension

Rear Suspension

.035 in. (0.9 mm)

Pressurized Wet Sump

Automatic PVT (Polaris Variable Transmission)

MacPherson strut with 8.2" (21 cm) travel

Progressive rate with 8.75" (22 cm) travel

148

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SPECIFICATIONS

Sportsman X2 800 EFI

Transmission

Automatic EBS (Engine Braking System)

with E-Z Shift H/L/N/R/P

Gear Reduction, Low

Gear Reduction, Reverse

Gear Reduction, High

Drive Ratio, Front

Tires/Pressure, Front

Tires/Pressure, Rear

Brakes, Front

23.91:1

21.74:1

8.28:1

3.82:1

25x8-12 / 5 psi

25x11-12 / 5 psi

Single-Control Hydraulic Disc

Foot-Activated Hydraulic Disc

Hydraulic lock, all wheel

Brakes, Rear

Brake, Auxiliary

Brake, Parking

Headlight

1 Single Beam on Headlight Pod (50 watt)

2 Single Beam on Bumper (37.5 watt)

Taillights

8.26 watts

26.9 watts

LCD

Brake Light

Instrument Cluster

Clutching (EBS Models)

Altitude

Shift

Weight

Drive Clutch

Spring

Driven

Clutch

Spring

Helix*

Meters

(Feet)

0-1800

21-74

66-56-33

BA500

(0-6000)

PN 5632117

Red/White

Red

PN 7043349 PN 3234452

EBS

1800-3700

(6000-12000)

21-70.5

PN 5632106

PN 3234604

NOTE: *EBS models require no helix/spring adjustment

149

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WARRANTY

LIMITED WARRANTY

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

ITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against

defects in material or workmanship. Polaris also gives a one year limited warranty on

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

charges for repair or replacement of defective parts which are covered by this warranty.

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

consumer during the warranty period through a Polaris dealer.

REGISTRATION

At the time of sale, the Warranty Registration Form must be completed by your dealer

and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will

record the registration for warranty. No verification of registration will be sent to the

purchaser as the copy of the Warranty Registration Form will be the warranty entitle-

ment. If you have not signed the original registration and received the customer copy,

please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE

ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS.

Initial dealer preparation and set-up of your ATV is very important in ensuring trouble-

free operation. Purchasing a machine in the crate or without proper dealer set-up will

void your warranty coverage.

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WARRANTY

WARRANTY COVERAGE AND EXCLUSIONS:

LIMITATIONS OF WARRANTIES AND REMEDIES

The Polaris limited warranty excludes any failures that are not caused by a defect in

material or workmanship. This warranty does not cover accidental damage, normal wear

and tear, abuse or improper handling. This warranty also does not cover any ATV that

has been altered structurally, modified, neglected, improperly maintained, used for rac-

ing, or used for purposes other than for which it was manufactured, or for any damages

which occur during trailer transit or as a result of unauthorized service or the use of

unauthorized parts. In addition, this warranty does not cover physical damage to paint or

finish, stress cracks, tearing or puncturing of upholstery material, corrosion, or defects in

parts, components or the ATV due to fire, explosions or any other cause beyond Polaris'

control.

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

are not compatible with the ATV. The exclusive remedy for breach of this warranty shall

be, at Polaris' exclusive option, repair or replacement of any defective materials, or com-

ponents or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE

ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR-

RANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI-

DENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION,

WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY

OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. Some

states do not permit the exclusion or limitation of incidental or consequential damages

or implied warranties, so the above limitations or exclusions may not apply to you if

inconsistent with controlling state law.

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WARRANTY

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE

IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-

TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX

MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS

WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limi-

tations on how long an implied warranty lasts, so the above limitation may not apply to

you if inconsistent with controlling state law.

HOW TO OBTAIN WARRANTY SERVICE

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

repair Polaris ATVs. When requesting warranty service you must present your copy of

the Warranty Registration form to the dealer. (THE COST OF TRANSPORTATION TO

AND FROM THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests that you

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

perform warranty service.

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

any additional assistance they will contact the appropriate person at Polaris.

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

vary from state to state.

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

terms will remain in effect.

Engine Oil

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

ommend the use of Polaris engine oil for your ATV.

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

by warranty.

SPARK ARRESTOR

Polaris warrants that the spark arrestor in this vehicle will meet the efficiency require-

ments of 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.

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WARRANTY

Exported Vehicles

EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-

RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD

OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCA-

TION.

This policy does not apply to vehicles that have received authorization for export from

Polaris Industries. Dealers may not give authorization for export. You should consult an

authorized dealer to determine this vehicle's warranty or service bulletin coverage if you

have any questions.

This policy does not apply to vehicles registered to government officials or military per-

sonnel on assignment outside the country of the selling dealer's authorized location.

This policy does not apply to Safety Recalls.

How to Get Service

In the Country where your vehicle was purchased:

Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you

move or are traveling within the country where your vehicle was purchased, Warranty or

Service Bulletin repairs may be requested from any authorized Polaris dealer who sells

the same line as your vehicle.

Outside the Country where your vehicle was purchased:

If you are traveling temporarily outside the country where your vehicle was purchased,

you should take your vehicle to an authorized Polaris dealer. You must show the dealer

photo identification from the country of the selling dealer's authorized location as proof

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

form the warranty repair.

If You Move:

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

customs department of the destination country before you move. Vehicles importation

rules vary considerably from country to country. You may be required to present docu-

mentation of your move to Polaris Industries in order to continue your warranty cover-

age. You may also be required to obtain documentation from Polaris Industries in order

to register your vehicle in your new country.

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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 procedure set out above, your vehicle will no longer be eligible for war-

ranty or service bulletin coverage of any kind. (Vehicles registered to Government offi-

cials or military personnel on assignment outside of the country where the vehicle was

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

For questions call Polaris Customer Assistance:

United States: 1-888-704-5290

Canada: 1-204-925-7100

154

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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 deliv-

ered to the original retail purchaser 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 recircula-

tion, 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.

The exclusive remedy for breach of this limited warranty shall be, at the exclusive

option of Polaris, repair or replacement of any defective materials, components or prod-

ucts. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE

ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR-

RANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI-

DENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY

DESCRIPTION,WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR-

RANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR

OTHERWISE.

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY

IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-

TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY

PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS WARRAN-

TIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on

how long an implied warranty lasts, so the above limitation may not apply if it is incon-

sistent with the controlling state law.

This limited warranty excludes failures not caused by a defect in material or workman-

ship.This limited warranty does not cover damage due to accidents, abuse or improper

handling, maintenance or use. This limited warranty also does not cover any engine that

has been structurally altered, or any engine that has been used in racing competition.

This limited warranty also does not cover physical damage, corrosion or defects caused

by fire, explosions or other similar causes beyond the control of Polaris.

If you have any questions regarding your warranty rights and responsibilities, you

should contact the Polaris Warranty Department at 1-888-704-5290.

155

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MAINTENANCE LOG

Present this section of your manual to your dealer each time your vehicle is serviced.

This will provide you and future owners with an accurate log of maintenance and ser-

vices performed.

DATE

MILES (KM)

OR HOURS

TECHNICIAN

SERVICE PERFORMED / COMMENTS

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MAINTENANCE LOG

DATE

MILES (KM)

OR HOURS

TECHNICIAN

SERVICE PERFORMED / COMMENTS

157

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INDEX

0-10

4X4 Switch . . . . . . . . . . . . . . . . . . . 38

Cold Weather Operation . . . . . . . . . . 63

Consumer Product Safety . . . . . . . . . 20

Coolant Bottle . . . . . . . . . . . . . . . . . 102

Coolant, Radiator. . . . . . . . . . . . . . . 103

Cooling System . . . . . . . . . . . . 102-103

Corrosion Removal, Chrome. . . . . . 131

Crankcase Emission Control System. 84

Accessories . . . . . . . . . . . . . . . . . . 134

Active Descent Control Fluid . 100-101

Active Descent Control System. . . . 49

ADC System . . . . . . . . . . . . . . . . . . 49

Age Restrictions. . . . . . . . . . . . . . . . 14

Air Filter . . . . . . . . . . . . . . . . . . . . 109

All Wheel Drive System . . . . . . . 47-48

Auxiliary Foot Brake. . . . . . . . . . . 104

Demand Drive Capacities . . . . . . . . . 99

Demand Drive Fluid . . . . . . . . . . . . 100

Differential Switch . . . . . . . . . . . . . . 39

Disengaging Active Descent Control 49

Drive Belt Wear/Burn . . . . . . . . . . . 139

Drivetrain Break-In . . . . . . . . . . . . . . 61

Driving Downhill. . . . . . . . . . . . . . . . 75

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

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

Driving on Slippery Surfaces . . . . . . 72

Driving Over Obstacles . . . . . . . . . . . 80

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

Driving Through Water . . . . . . . . 78-79

Driving Uphill . . . . . . . . . . . . . . . . . . 73

Driving with a Passenger. . . . . . . 70-71

Battery . . . . . . . . . . . . . . . . . . 123-128

Charging (Conventional) . . . . 127

Charging (Sealed) . . . . . . 127-128

Conventional . . . . . . . . . . . . . 123

Fluid (Conventional) . . . . . . . 126

Installation . . . . . . . . . . . . . . . 125

Removal. . . . . . . . . . . . . . . . . 124

Storage. . . . . . . . . . . . . . . . . . 126

Belt Life. . . . . . . . . . . . . . . . . . . . . . 45

Boots . . . . . . . . . . . . . . . . . . . . . . . . 13

Brake Fluid, Auxiliary Foot Brake . 44

Brake Fluid, Main Brake System. . . 42

Brake Lever . . . . . . . . . . . . . . . . . . . 41

Brake, Foot . . . . . . . . . . . . . . . 44, 104

Brake, Hand Lever. . . . . . . . . . . . . 104

Brake, Parking . . . . . . . . . . . . . . . . . 43

Brakelight Lamp Replacement . . . 115

Brakes . . . . . . . . . . . . . . . . . . . . . . 104

Break-In Period . . . . . . . . . . . . . . . . 61

Breather Filter . . . . . . . . . . . . . . . . 110

Breather Hose . . . . . . . . . . . . . . . . 110

Electromagnetic Interference. . . . . . . 84

Emissions Limited Warranty. . . . . . 155

Engaging 4X4 . . . . . . . . . . . . . . . . . . 48

Engaging Active Descent Control. . . 49

Engine Break-In. . . . . . . . . . . . . . . . . 61

Engine Fogging . . . . . . . . . . . . . . . . 133

Engine Oil . . . . . . . . . . . . . . . . . . 90-97

Engine Stop Switch . . . . . . . . . . . . . . 38

Equipment Modifications . . . . . . . . . 21

Exhaust Emission Control System . . 84

Eye Protection . . . . . . . . . . . . . . . . . . 13

Camber Adjustment. . . . . . . . . . . . 136

Cargo . . . . . . . . . . . . . . . . . . . . . . 65-67

Cargo Loading . . . . . . . . . . . . . . . . . 64

Caster Adjustment . . . . . . . . . . . . . 136

Chrome Wheel Care . . . . . . . . . . . 131

Cleaning and Storage. . . . . . . . 129-134

Clock, Setting Time. . . . . . . . . . . . . 55

Clothing . . . . . . . . . . . . . . . . . . . . . . 13

Clutching

Fluid

Active Descent Control . . 100-101

Brake . . . . . . . . . . . . . . . . . . . . . 42

Coolant . . . . . . . . . . . . . . 102-103

Demand Drive . . . . . . . . . . 99-100

Engine Oil . . . . . . . . . . . . . . . . . 90

500 EFI . . . . . . . . . . . . . . . . . 145

700 EFI . . . . . . . . . . . . . . . . . 147

800 EFI . . . . . . . . . . . . . . . . . 149

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INDEX

Fluid Change

Lights . . . . . . . . . . . . . . . . . . . 112-115

Headlight Housing . . . . . . . . . 114

Headlight Lamp . . . . . . . . . . . 112

High Beam Adjustment . . . . . 113

Low Beam Adjustment. . . . . . 113

Lower Headlamp Replacement 115

Taillight/Brakelight/Worklight 115

Low Range Use. . . . . . . . . . . . . . . . 122

Lubrication Guide. . . . . . . . . . . . . . . 89

ADC . . . . . . . . . . . . . . . . . . . . 101

Demand Drive. . . . . . . . . . . . . 100

Engine Oil (500) . . . . . . . . . .93-95

Engine Oil (700/800) . . . . . 96-97

Transmission. . . . . . . . . . . . . . . 99

Fluid Level

ADC . . . . . . . . . . . . . . . . . . . . 101

Brake. . . . . . . . . . . . . . . . . . 42-44

Coolant . . . . . . . . . . . . . . 102-103

Demand Drive. . . . . . . . . . . . . 100

Engine Oil (500) . . . . . . . . . . . . 91

Engine Oil (700/800) . . . . . . . . 92

Transmission. . . . . . . . . . . . . . . 98

Foot Brake, Auxiliary . . . . . . . . . . . . 44

Footwell Removal. . . . . . . . . . . . . . 106

Fuel Filter (500 EFI). . . . . . . . . . . . . 45

Fuel Recommendations. . . . . . . . . . . 45

Fuel Safety . . . . . . . . . . . . . . . . . . . . 60

Fuel Tank Cap. . . . . . . . . . . . . . . . . . 45

Fuse Replacement. . . . . . . . . . . . . . 111

Maintenance Chart . . . . . . . . . . . 85-88

Master Cylinder . . . . . . . . . . . . . . . . 42

Mode Switch. . . . . . . . . . . . . . . . . . . 38

Modifications . . . . . . . . . . . . . . . . . . 21

Noise Emission Control System . . . . 84

Oil

Engine. . . . . . . . . . . . . . . . . 90-97

Transmission. . . . . . . . . . . . 98-99

Oil Change

Engine (500 EFI) . . . . . . . . 93-95

Engine (700/800 EFI) . . . . . 96-97

Transmission. . . . . . . . . . . . . . . 99

Oil Level

Engine (500 EFI) . . . . . . . . . . . 91

Engine (700/800 EFI) . . . . . . . . 92

Transmission. . . . . . . . . . . . . . . 98

Oil Pump Priming (500 EFI) . . . . . . 95

Oil Recommendations . . . . . . . . . . . 90

Operation on Public Lands . . . . . . . . 84

Override Switch . . . . . . . . . . . . . . . . 38

Gear Selector. . . . . . . . . . . . . . . . . . . 45

Gloves . . . . . . . . . . . . . . . . . . . . . . . . 13

Hand Brake . . . . . . . . . . . . . . . . . . . 104

Handlebar Adjustment . . . . . . . . . . 137

Hauling Cargo. . . . . . . . . . . . . . . 64-67

Headlight Housing Replacement . . 114

Headlight Lamp Replacement . . . . 112

Headlight Switch. . . . . . . . . . . . . . . . 39

Helmet. . . . . . . . . . . . . . . . . . . . . . . . 12

High Beam Adjustment . . . . . . . . . 113

High Range Use . . . . . . . . . . . . . . . 122

Hub Tightening. . . . . . . . . . . . . . . . 107

Parking Brake . . . . . . . . . . . . . . . . . . 43

Parking on an Incline . . . . . . . . . . . . 81

Passenger Seat . . . . . . . . . . . . . . 50-51

Periodic Maintenance Chart . . . . 85-88

Polaris Product List. . . . . . . . . . . . . 143

Polishing the Vehicle . . . . . . . . . . . 130

Pre-Ride Checklist . . . . . . . . . . . . . . 62

PVT Break-In . . . . . . . . . . . . . . . . . . 61

PVT Drying . . . . . . . . . . . . . . . . . . 122

PVT System . . . . . . . . . . . . . . 120-122

Idle RPM Adjustment . . . . . . . . . . . 138

Immersion Maintenance . . . . . . . . . 118

Instrument Cluster. . . . . . . . . . . . 52-59

Key Switch . . . . . . . . . . . . . . . . . . . . 38

K-Turn . . . . . . . . . . . . . . . . . . . . 76-77

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INDEX

Recoil Housing (500 EFI) . . . . . . . 117

Recoil Starter (500 EFI). . . . . . . . . . 46

Reverse Operation . . . . . . . . . . . . 82-83

Reverse Override Switch. . . . . . . . . 38

Rider Information Center. . . . . . . 53-59

Rider Safety . . . . . . . . . . . . . . . . . 14-37

Riding Gear . . . . . . . . . . . . . . . . . 12-13

Taillight Lamp Replacement . . . . . . 115

Throttle Body Adjustment. . . . . . . . 138

Throttle Cable Freeplay Adjustment 138

Throttle Lever . . . . . . . . . . . . . . . . . . 40

Tires . . . . . . . . . . . . . . . . . . . . 107-108

Tire Tread Depth . . . . . . . . . . . 107

Wheel Installation . . . . . . . . . . 108

Wheel Nut Torque . . . . . . . . . . 108

Wheel Removal . . . . . . . . . . . . 107

Toe Alignment. . . . . . . . . . . . . . . . . 105

Towing Capacities. . . . . . . . . . . . . . . 66

Towing Loads . . . . . . . . . . . . . . . . . . 66

Training . . . . . . . . . . . . . . . . . . . . . . . 15

Transmission . . . . . . . . . . . . . . . . . . . 45

Transmission Oil . . . . . . . . . . . . . 98-99

Transporting the ATV . . . . . . . . . . . 135

Turning Around on a Hill . . . . . . 76-77

Turning the Vehicle. . . . . . . . . . . . . . 69

Safety Decals. . . . . . . . . . . . . . . . . 6-11

Age 16 Warning. . . . . . . . . . . . . 6

Box Warning . . . . . . . . . . . . . . 11

Clutch Cover Warning. . . . . . . 10

Discretionary Warning. . . . . . . . 6

General Warning . . . . . . . . . . . . 7

Passenger Safety . . . . . . . . . . . . 8

Rack Warning, Front and Rear 10

Reverse Override Warning . . . 11

Tire Pressure/Load Warning . . . 9

Safety Training . . . . . . . . . . . . . . . . 15

Service Interval Programming. . . . . 57

Severe Use . . . . . . . . . . . . . . . . . . . . 85

Side Panel Removal. . . . . . . . . . . . 106

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

Signal Words . . . . . . . . . . . . . . . . . . 16

Spark Arrestor . . . . . . . . . . . . . . . . 119

Spark Plug Inspection . . . . . . . 116-117

Spark Plug Recommendations. . . . 116

Spark Plug Torque Specification. . 116

Spark Plugs . . . . . . . . . . . . . . . 116-117

Specifications. . . . . . . . . . . . . . 144-149

Spring Adjustment, Rear Shock . . 136

Starting the Engine . . . . . . . . . . . . . 63

Steering Assembly. . . . . . . . . . . . . 106

Storage. . . . . . . . . . . . . . . . . . . 129-134

Storage Tips. . . . . . . . . . . . . . . 132-134

Switches . . . . . . . . . . . . . . . . . . . 38-39

4X4 Switch . . . . . . . . . . . . . . . 38

Differential Switch. . . . . . . . . . 39

Engine Stop Switch . . . . . . . . . 38

Headlight Switch . . . . . . . . . . . 39

Main Key Switch. . . . . . . . . . . 38

Mode/Reverse Override Switch 38

Worklight Switch. . . . . . . . . . . 39

Vehicle Identification Numbers. . . . . . 5

Vehicle Immersion . . . . . . . . . . . . . 118

VIN . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Warning Symbols . . . . . . . . . . . . . . . 16

Washing the Vehicle . . . . . . . . 129-130

Wheel Installation . . . . . . . . . . . . . . 108

Wheel Nut Torque Specifications . . 108

Wheel Removal . . . . . . . . . . . . . . . . 107

Worklight Lamp Replacement. . . . . 115

Worklight Switch. . . . . . . . . . . . . . . . 39

160

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