Polaris Offroad Vehicle Scrambler 500 4x4 User Manual

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WARNING

The engine exhaust from this

product contains chemicals known

to cause cancer, birth defects or

other reproductive harm.

A card containing important ATV safety information should be attached

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

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

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We’ve created a Web site just for you!

S Technical tips

S New product introductions

S Event schedules

S Parts and Service Manual information

S Exciting details about The Way Out

Check it out...

www.polarisindustries.com/owner

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

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

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

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

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

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

expressly prohibited. Printed in U.S.A.

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WELCOME

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

world-wide family of Polaris owners. We proudly produce an exciting

line of utility and recreational products.

Polaris Recreational and Utility Vehicles

S Snowmobiles

S All-terrain vehicles (ATVs)

S Watercraft

S Victory motorcycles

S RANGER utility vehicles

Polaris Professional Series Workmobilest

S Utility Task Vehiclest (UTVs)

S Personal Task Vehiclest (PTVs)

S All-Surface Loaders (ASLs)

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

recreational vehicles manufactured in the world today. Many years of

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

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

produced.

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

instructions and recommendations in this owner’s manual. Your

manual contains instructions for minor maintenance, but information

about major repairs is outlined in the Polaris Service Manual and

should be performed only by a Factory Certified Master Service Dealer

(MSD) Technician.

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

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

service needs during, and after, the warranty period.

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

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

Have your accessories and clothing delivered right to your door!

Polaris, Polaris The Way Out, and Workmobiles are registered

trademarks of Polaris Industries Inc.

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TABLE OF CONTENTS

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

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

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

FEATURES AND CONTROLS . . . . . . . . . . . . . . . 37

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

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

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

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 114

POLARIS PRODUCTS . . . . . . . . . . . . . . . . . . . . . 117

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . 118

WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

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VEHICLE IDENTIFICATION NUMBERS

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

serial number are important for model identification when registering

your vehicle, when obtaining insurance, and when ordering

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

to the recovery and identification of your vehicle.

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

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

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

replaced. See your Polaris dealer.

NOTE: Record your vehicle’s ID numbers and key number (2) in the

spaces provided.

31XX

Frame VIN:

Vehicle Model Number:

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

Key Number:

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SAFETY

Operator Safety

WARNING

Failure to follow the warnings contained in this manual can result

in severe injury or death.

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

vehicle handles differently than other vehicles, such as

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

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

over obstacles, if you fail to take proper precautions.

Read and understand your owner’s manual and all warnings

before operating a Polaris ATV.

Age Restrictions

This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited

for anyone under 16 years of age.

Know Your Vehicle

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

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

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

information about all aspects of your vehicle, including safe operating

procedures.

Safety Training

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

safety training course that covers all aspects of vehicle safety. You were

also provided with printed materials that explain safe operating

procedures. You should review this information on a regular basis.

If you purchased a used Polaris ATV from a party other than a Polaris

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

Polaris dealer.

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

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

We strongly advise you to strictly follow the recommended

maintenance program outlined in your owner’s manual. This

preventive maintenance program is designed to ensure that all critical

components on your vehicle are thoroughly inspected at specific

intervals.

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SAFETY

Operator Safety

The following signal words and symbols appear throughout this

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

and symbols are used. Become familiar with their meanings before

reading the manual.

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

you to the potential for personal injury.

WARNING

The safety alert warning indicates a potential hazard that may

result in serious injury or death.

CAUTION

The safety alert caution indicates a potential hazard that may

result in minor personal injury or damage to the machine.

CAUTION

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

machine.

NOTE

A note will alert you to important information or instructions.

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SAFETY

Operator Safety

WARNING

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

instructions and procedures, which are outlined in further detail

within your owner’s manual.

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

procedures described.

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

course. Beginners should receive training from a certified instructor.

Contact an authorized Polaris ATV dealer or call Polaris at

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

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

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

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

ty training course.

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

walks, driveways, parking lots, and streets.

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

a dirt or gravel road.

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

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

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

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

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

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

S Never attempt wheelies, jumps or other stunts.

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

operating condition. Always follow the inspection and maintenance

procedures and schedules outlined in your owner’s manual.

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

rests of the ATV during operation.

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

miliar terrain. Be alert to changing terrain conditions.

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

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

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

speeds. Do not turn at excessive speeds.

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SAFETY

Operator Safety

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

it’s been involved in an accident.

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

Practice on smaller hills before attempting larger hills.

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

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

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

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

the top of a hill at high speed.

S Always follow proper procedures for going downhill and for braking

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

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

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

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

sible.

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

Avoid hills with excessively slippery or loose surfaces. Shift your

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

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

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

steep hill when possible.

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

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

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

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

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

Turn the ATV around and remount following the procedure de-

scribed in this manual.

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

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

Always follow proper procedures when operating over obstacles as

described in this manual.

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

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

ding or sliding out of control.

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

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

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

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

changes.

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SAFETY

Operator Safety

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

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

friction to dry out the pads.

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

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

avoid turning at sharp angles.

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

always maintain proper tire pressure.

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

sories.

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

properly distributed and securely attached. Reduce speed and follow

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

greater distance for braking.

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

prevent unauthorized use or accidental starting.

FOR MORE INFORMATION ABOUT ATV SAFETY, call the Con-

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

Polaris at 1-800-342-3764.

Equipment Modifications

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

public. Therefore, we strongly recommend that consumers do not

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

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

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

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

injury.

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

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

the vehicle, that increase its speed or power.

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

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

handling characteristics of the vehicle. Use only Polaris-approved

accessories, and familiarize yourself with their function and effect on

the vehicle.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating this ATV without proper instruction.

WHAT CAN HAPPEN

The risk of an accident is greatly increased if the operator

does not know how to operate the ATV properly in different

situations and on different types of terrain.

HOW TO AVOID THE HAZARD

Beginning and inexperienced operators should complete the

certified training course offered by Polaris. Operators should

regularly practice the skills learned in the course and the

operating techniques described in the owner’s manual.

For more information about the training course, contact an

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

WARNING

POTENTIAL HAZARD

Failure to follow the age recommendations for this ATV.

WHAT CAN HAPPEN

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

minimum age recommendation operates an ATV.

Even though a child may be within the recommended age group

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

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

be susceptible to accident or injury.

HOW TO AVOID THE HAZARD

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

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Carrying a passenger on an ATV.

WHAT CAN HAPPEN

Carrying a passenger greatly reduces the operator’s ability to

balance and control the ATV, which could cause an accident

and injury to the operator and/or passenger.

HOW TO AVOID THE HAZARD

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

allow the operator to shift position as needed during operation.

It is not intended for carrying passengers.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating an ATV on paved surfaces, including sidewalks,

paths, parking lots, and driveways.

WHAT CAN HAPPEN

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

surfaces may seriously affect the handling and control of the

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

HOW TO AVOID THE HAZARD

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

travel slowly and avoid sudden turns or stops.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating this ATV on public streets, roads or highways.

WHAT CAN HAPPEN

The ATV could collide with another vehicle.

HOW TO AVOID THE HAZARD

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

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

operate ATVs on public streets, roads and highways.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating this ATV without wearing an approved helmet, eye

protection and protective clothing.

WHAT CAN HAPPEN

Operating an ATV without an approved helmet increases the

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

accident.

Operating without eye protection could result in an accident

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

of an accident.

HOW TO AVOID THE HAZARD

Always wear an approved helmet that fits properly.

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

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

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating the ATV after consuming alcohol or drugs.

WHAT CAN HAPPEN

Consumption of alcohol and/or drugs could seriously affect

operator judgment. Reaction time may be slower and operator

balance and perception could be affected.

Consuming alcohol and/or drugs before or while operating an

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

HOW TO AVOID THE HAZARD

Never consume alcohol or drugs before or while operating an

ATV.

WARNING

POTENTIAL HAZARD

Operating the ATV at excessive speeds.

WHAT CAN HAPPEN

Excessive speed increases the operator’s chance of losing

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

HOW TO AVOID THE HAZARD

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

visibility and operating conditions, and your experience.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Attempting wheelies, jumps and other stunts.

WHAT CAN HAPPEN

Attempting stunts increases the chance of an accident, including

an overturn.

HOW TO AVOID THE HAZARD

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

driving.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Failure to inspect the ATV before operating.

Failure to properly maintain the ATV.

WHAT CAN HAPPEN

Poor maintenance increases the possibility of an accident or

equipment damage.

HOW TO AVOID THE HAZARD

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

safe operating condition.

Always follow the inspection and maintenance procedures and

schedules described in the owner’s manual.

WARNING

POTENTIAL HAZARD

Removing hands from the handlebars or feet from the

footrests during operation.

WHAT CAN HAPPEN

Removing even one hand or foot can reduce ability to

control the vehicle or could cause loss of balance and

ejection from the ATV.

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

could come into contact with the rear wheels and lead to

accident or injury.

HOW TO AVOID THE HAZARD

Always keep both hands on the handlebars and both feet

on the footrests of the ATV during operation.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Failure to use extra caution when operating the ATV on unfamiliar

terrain.

WHAT CAN HAPPEN

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

could cause loss of control or overturn.

HOW TO AVOID THE HAZARD

Travel slowly and use extra caution when operating on unfamiliar

terrain. Always be alert to changing terrain conditions.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Failure to use extra caution when operating on excessively

rough, slippery or loose terrain.

WHAT CAN HAPPEN

Operating on excessively rough, slippery or loose terrain could

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

accident or overturn.

HOW TO AVOID THE HAZARD

Do not operate on excessively rough, slippery or loose terrain

until you’ve learned and practiced the skills necessary to

control the ATV on such terrain.

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

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Turning improperly.

WHAT CAN HAPPEN

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

or overturn.

HOW TO AVOID THE HAZARD

Always follow proper procedures for turning as described in the

owner’s manual.

Practice turning at slow speeds before attempting to turn at

faster speeds.

Never turn at excessive speed.

WARNING

POTENTIAL HAZARD

Operating on excessively steep hills.

WHAT CAN HAPPEN

The vehicle may overturn.

HOW TO AVOID THE HAZARD

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

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

Practice on smaller hills before attempting large hills.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Climbing hills improperly.

WHAT CAN HAPPEN

Improper hill climbing could cause loss of control or overturn.

HOW TO AVOID THE HAZARD

Always follow proper procedures for climbing hills as described

in the owner’s manual.

Always check the terrain carefully before ascending any hill.

Never operate the ATV on hills steeper than 25_.

Never climb hills with excessively slippery or loose surfaces.

Shift your weight forward.

Never open the throttle suddenly while traveling uphill. The ATV

could flip over backwards.

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

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

side of the hill.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Traveling downhill improperly.

WHAT CAN HAPPEN

Improperly descending a hill could cause loss of control or

overturn.

HOW TO AVOID THE HAZARD

Always follow proper procedures for traveling down hills as

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

is required when braking while traveling downhill. See page

62.

Always check the terrain carefully before you descending a hill.

Shift your weight backward.

Never travel down a hill at high speed.

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

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

hill when possible.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Improperly crossing hills and turning on hills.

WHAT CAN HAPPEN

Improperly crossing or turning as hills could cause loss of control

or overturn.

HOW TO AVOID THE HAZARD

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

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

the owner’s manual. See page 63. Use extra caution when

turning on any hill.

Avoid crossing the side of a steep hill.

When crossing the side of a hill:

Always follow proper procedures as described in the owner’s

manual.

Avoid hills with excessively slippery or loose surfaces.

Shift your weight to the uphill side of the ATV.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Stalling, rolling backwards or

improperly dismounting while

climbing a hill.

WHAT CAN HAPPEN

The vehicle could overturn.

HOW TO AVOID THE

HAZARD

Maintain steady speed when

climbing a hill.

If all forward speed is lost:

Keep your weight uphill.

Apply the single lever brake gradually.

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

lock the parking brake.

If the ATV begins rolling backwards:

Keep weight uphill.

Never apply engine power.

Never apply the auxiliary rear brake while rolling backwards.

Apply the single-lever brake gradually.

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

then lock the parking brake.

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

straight uphill.

Turn the ATV around and remount, following the procedure

described in the owner’s manual. See page 63.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Improperly operating over obstacles.

WHAT CAN HAPPEN

Operating over obstacles could cause loss of control or overturn.

HOW TO AVOID THE HAZARD

Before operating in a new area, check for obstacles.

Avoid operating over large obstacles such as rocks and fallen

trees when possible. If unavoidable, use extreme caution and

always follow proper procedures as outlined in the owner’s

manual.

WARNING

POTENTIAL HAZARD

Skidding or sliding.

WHAT CAN HAPPEN

Skidding or sliding can cause loss of control.

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

HOW TO AVOID THE HAZARD

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

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

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating the ATV through deep or fast-flowing water.

WHAT CAN HAPPEN

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

which could lead to an accident or overturn.

HOW TO AVOID THE HAZARD

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

If it’s unavoidable to enter water that exceeds the

recommended maximum depth (see page 64), travel slowly,

balance your weight carefully, avoid sudden movements, and

maintain a slow and steady forward motion. Do not make

sudden turns or stops, and do not make sudden throttle

changes.

Wet brakes may have reduced stopping ability. Always test

the brakes after leaving water. If necessary, apply them

several times to let friction dry out the pads.

WARNING

POTENTIAL HAZARD

Improperly operating in reverse.

WHAT CAN HAPPEN

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

severe injury.

HOW TO AVOID THE HAZARD

Before shifting into reverse gear, always check for obstacles or

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

slowly.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating this ATV with improper tires, or with improper or

uneven tire pressure.

WHAT CAN HAPPEN

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

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

HOW TO AVOID THE HAZARD

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

Always maintain proper tire pressure as specified 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

Operator Safety

WARNING

POTENTIAL HAZARD

Overloading the ATV or carrying/towing cargo improperly.

WHAT CAN HAPPEN

Overloading and towing can cause changes in vehicle handling,

which could lead to loss of control or an accident.

HOW TO AVOID THE HAZARD

Never exceed the stated load capacity for this ATV.

Cargo should be properly distributed and securely attached.

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

greater distance for braking.

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

cargo or pulling a trailer. See page 54.

WARNING

POTENTIAL HAZARD

Operating on frozen bodies of water.

WHAT CAN HAPPEN

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

fall through the ice.

HOW TO AVOID THE HAZARD

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

confident that the ice is thick enough and sound enough to

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

created by a moving vehicle, exercise extreme caution.

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SAFETY

Operator Safety

WARNING

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

the vehicle resulting in serious injury or death. Always remove

the ignition key when the vehicle is not in use.

WARNING

After any overturn or accident, have a qualified service dealer

inspect the entire vehicle for possible damage, including (but

not limited to) brakes, throttle and steering systems.

WARNING

Safe operation of this rider-active vehicle requires good

judgement and physical skills. Persons with cognitive or

physical disabilities who operate this vehicle have an

increased risk of overturn and loss of control, which could

result in severe injury or death.

CAUTION

Always keep combustible materials away from the exhaust

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

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SAFETY

Fuel Safety

WARNING

Gasoline is highly flammable and explosive under certain

conditions.

S Always exercise extreme caution whenever handling gaso-

line.

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

well ventilated area.

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

area where refueling is performed or where gasoline is

stored.

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

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

off with soap and water and change clothing.

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

gine exhaust fumes are poisonous and can cause loss of

consciousness or death in a short time.

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

WARNING

The engine exhaust from this product contains chemicals known

to cause cancer, birth defects or other reproductive harm.

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

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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.

WARNING

25°

DNever operate this vehicle on HILLS steeper than 25 degrees

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

and brakes gradually.

DREVERSE operation can bedangerous, evenat lowspeeds. Steeringbe-

comes difficult. To prevent flipover, avoid sudden braking or sharp turns.

DUse OVERRIDE for reverse speed limiter with caution. To prevent loss

of control, never activate override button with open throttle.

DPARKING BRAKE may relax when used for more than 5 minutes. When

parking on grades, leave shift in forward.

7079085

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 AWD. See

Owner’s Manual.

7079604

WARNING

Moving parts hazard under belt-clutch guard. To

prevent serious injury, do not operate vehicle

with guard removed.

Do not modify engine or clutch. Doing so can

cause part failure, possible imbalance, and

excessive engine RPM, which can result in serious

injury or death.

NO STEP

7078689

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SAFETY

Safety Decals and Locations

WARNING

Improper ATV use can result in SEVERE INJURY or DEATH

ALWAYS USE

AN APPROVED

HELMET AND

PROTECTIVE

GEAR

NEVER USE

ON PUBLIC

ROADS

NEVER CARRY

PASSENGERS

NEVER USE

WITH DRUGS

OR ALCOHOL

NEVER operate:

ALWAYS:

WARNING

7077920

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SAFETY

Safety Decals and Locations

ALL WHEEL

WARNING

DRIVE

SWITCH

Do not push switch

to engage AWD if

the rear wheels are

spinning. This may

cause severe drive

shaft and clutch

damage.

Operating this ATV if you are under

the age of 16 increases your chance

of severe injury or death.

See your Owner’s

Manual.

NEVER operate this ATV if you are

under age 16.

7079780

7078253

Chain Freeplay Is Important.

Adjust Freeplay to 3/16″ - 3/8″

DO NOT Overtension.

See Owner’s Manual.

Torque Nut on Eccentric Bolts:

To 30 Ft. Lbs. (For models

without a hitch).

To 40 Ft. Lbs. (For models with

a hitch).

7078572

MANUFACTURED

BY: POLARIS IND. INC.

DATE:

VIN:

THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT

INTENDED FOR USE ON PUBLIC ROADS.

CE VÉHICULE EST UN VÉHICULE TOUT TERRAIN QUI NiEST

PAS DESTINÉ À ÊTRE UTILISÉ SUR LES CHEMINS PUBLICS.

7171492

Canadian Certification Decal

Under Seat

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SAFETY

Safe Riding Gear

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

special protective clothing for comfort and to reduce the chance of

injury.

1. Helmet

Your helmet is the most important piece

of protective gear for safe riding. A

helmet can prevent a severe head injury.

Select an approved helmet that meets or

exceeds your state’s safety standards

and bears either the Department of

Transportation (DOT) label, the

American National Standards Institute

label (ANSI z90.1), or the Snell

Memorial Foundation label.

2. Eye Protection

Do not depend on sunglasses for proper

eye protection. A pair of goggles or a

helmet face shield offer the best

protection for your eyes. They should

be kept clean and be of shatterproof

design (bearing the markings z2.1 or

VESC 8).

3. Gloves

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

protection.

4. Boots

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

moto-cross boots.

5. Clothing

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

Riding pants with kneepads and a jersey with shoulder pads provide

the best protection.

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FEATURES AND CONTROLS

Electrical Switches

WARNING

Activating the override switch while the throttle is open can

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

activate the override switch while the throttle is open.

Override Switch (1) (Reverse Speed Limiter) -

OFF RUN OFF

This vehicle is equipped with a reverse speed limiter

system. To gain additional power while backing,

depress the override switch. NOTE: The override

switch also allows activation of AWD in reverse, if

the AWD switch is on.

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

center RUN position and turn the main key switch clockwise past the

ON position. Release the key when the engine starts. NOTE: Turn off

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

lights.

WARNING

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

the vehicle resulting in serious injury or death. Always remove

the ignition key when the vehicle is not in use.

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

switch is in its OFF position. Its purpose is to provide the operator

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

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

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

electrical power to the vehicle, including the lights.

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FEATURES AND CONTROLS

WARNING

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

could result in an accident and serious injury or death.

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

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

caution and drive at reduced speeds in conditions of reduced

visibility such as fog, rain and darkness.

Light Switches

The light switch is located on the left

handlebar (1). It’s used to turn the

lights on and off and to switch the

lights from high beam to low beam.

NOTE: The lights won’t work unless

the key is in the ON position and the

shut-off switch is in the RUN position.

Indicator Lights

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

time the ATV is used.

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

Turn the key off to prevent battery drain.

1. Transmission Neutral Indicator

2. Transmission Reverse Indicator

3. High Temp Warning (displays if engine overheats)

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FEATURES AND CONTROLS

WARNING

Do not start or operate an ATV with sticking or improperly

operating throttle controls, which could cause an accident and

lead to severe injury or death.

Always contact your dealer for service repairs if throttle problems

arise.

Failure to check or maintain proper operation of the throttle

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

operation.

Always check the lever for free movement and return before

starting the engine. Also check occasionally during operation.

Throttle Lever

Engine speed and vehicle movement

are controlled by pressing the

throttle lever. The throttle lever (1)

is spring loaded. Engine speed

returns to idle when the lever is

released.

This ATV is equipped with Polaris

Electronic Throttle Control (ETC),

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

throttle cable should stick in an open position when the operator

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

wheels will cease.

WARNING

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

event of a throttle system malfunction and is provided for your

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

with any after market throttle mechanisms.

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FEATURES AND CONTROLS

Brake Lever

WARNING

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

of braking, which could cause an accident.

Never operate the ATV with a spongy-feeling brake lever.

The front and rear brakes are

applied by squeezing the brake

lever (1) toward the handlebar.

The front and rear brakes are

hydraulically activated disc type

brakes that are activated by only

one lever.

Always test brake lever travel and

master cylinder fluid level before

riding. When squeezed, the lever

should feel firm. Any sponginess would indicate a possible fluid leak

or low master cylinder fluid level, which must be corrected before

riding. Contact your dealer for proper diagnosis and repairs.

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FEATURES AND CONTROLS

Brakes

Check the brake fluid level in the

master cylinder before each use of

the ATV. The master cylinder (1) is

located on the left handlebar.

The fluid level can be seen through

an indicator window (2) on the top

of the master cylinder. This “eye”

will appear dark when the fluid level

is full. When fluid needs to be

added, the eye will be clear.

WARNING

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

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

brake fluid at the recommended level. Do not overfill.

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

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

brake fluid only. DO NOT OVERFILL. See page 117 for the part

numbers of Polaris products.

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

Parking Brake

WARNING

Operating the ATV while the parking brake is engaged could

result in an accident and serious injury or death.

Always check to be sure the parking brake is disengaged

before operating.

Setting the Parking Brake

1. Squeeze and release the brake lever two or

three times, then squeeze and hold.

2. Push the park brake lock (1)

forward to engage the brake.

Release the brake lever.

3. To release the parking brake lock,

squeeze and release the brake

lever. It will return to its unlocked

position.

Important Safeguards

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

ways block the wheels to prevent rolling.

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

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

position.

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

hill. Always block the wheels to prevent rolling.

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FEATURES AND CONTROLS

WARNING

Auxiliary Brake

Aggressively applying the auxiliary rear brake when backing

downhill may cause rear tipover, which could result in serious

injury or death. Use caution when applying the auxiliary brake.

Do not aggressively apply the auxiliary brake when going forward.

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

control and serious injury or death.

The auxiliary foot brake (1), is

located on the inside of the right

floorboard and is operated by the

right foot. The auxiliary brake

serves as a backup to the main

brake system if the main system

becomes inoperative.

If the rear wheels slide while

using the auxiliary brake, reduce

brake pedal pressure to brake the

rear wheels without skidding.

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

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

the fluid level between the maximum and minimum marks.

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FEATURES AND CONTROLS

Choke

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

procedure on page 51 for correct choke and throttle settings during

starting.

Fuel Valve

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

the vehicle, below the fender. It has three

positions:

OFF: For vehicle storage and when transporting.

ON: For normal operation.

RES: For reserve supply if main

supply is exhausted.

NOTE: There’s about a 7 to 10 mile

(11.2 to 16 km) range on reserve gas.

Always refill the gas tank as soon as

possible after using the reserve supply.

Always return the valve to the ON

position after refueling.

Fuel Tank

The fuel tank filler cap (2) is located

directly below the handlebar. Use

either leaded or unleaded gasoline with

a minimum pump octane number of

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

specifications section at the rear of this

manual for tank capacity.

Fuel Filter

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

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

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FEATURES AND CONTROLS

Automatic Transmission Gear Selector

The transmission gear selector (1)

is located on the right side of the

vehicle.

F: Forward

N: Neutral

R: Reverse

CAUTION

Shifting gears with the engine speed above idle or while the

vehicle is moving could cause transmission damage.

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

move the lever to the desired gear.

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

gear and lock the parking brake.

Maintaining shift linkage adjustment is important to assure proper

transmission function. See your dealer if you experience any shifting

problems.

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FEATURES AND CONTROLS

Recoil Starter

If the battery has been drained or

damaged and cannot start the

engine, use of the recoil starter (1)

will allow vehicle operation until

repairs can be made. The recoil

starter is located on the right side of

the machine.

Polaris 4-cycle engines are

equipped with automatic

decompressors. This makes recoil

starting possible by reducing the amount of compression during

starting. The decompressor senses when the engine is spinning fast

enough to start and restores compression when running.

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

(see page 42).

2. Shift the transmission into neutral.

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

switch is in the ON position. NOTE: If the engine is cold, use the

choke as outlined on page 51.

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

you can feel the engine strokes. NOTE: Every other stroke will

be a “compression stroke” and will make the rope harder to pull.

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

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

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

the rope abruptly and forcefully to start the engine.

6. Repeat steps 4-5 if necessary.

CAUTION

Extending the recoil starter rope until it stops can cause damage

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

it stops.

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

the recoil housing and damage components. Make sure the

handle is fully seated on the recoil housing, especially when

traveling in wet areas.

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FEATURES AND CONTROLS

All Wheel Drive (AWD) System

Polaris 4-wheel drive ATVs are

equipped with a unique, Polaris

exclusive, AWD system that’s

activated by a switch (1) on the right

handlebar. When the switch is off,

the ATV is in 2 wheel drive at all

times. When the switch is on, the

ATV is in AWD and the AWD

indicator light (2) will be on.

When in AWD, the front hubs will

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

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

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

the AWD switch is on. See page 37.

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

Engaging Wheel Hubs

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

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

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

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

while the front hubs are moving, the hubs will not disengage until the

rear wheels regain traction.

Engage the AWD switch before getting into conditions where front

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

throttle before switching to AWD.

CAUTION

Switching to AWD while the rear wheels are spinning may

cause severe drive shaft and hub damage. Always switch to

AWD while the rear wheels have traction or are at rest.

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FEATURES AND CONTROLS

All Wheel Drive (AWD) System

Disengaging Wheel Hubs

Although the hubs normally disengage when operating in reverse, one

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

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

engaged, steering effort increases but remains balanced from left to

right, and vehicle speed is somewhat restricted.

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

short distance. Then proceed in forward again.

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

return the ATV to your dealer for service.

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

AWD switch. See page 37.

WARNING

Operating with only one front hub engaged could result in loss

of control, accident, and severe injury or death. When hub

engagement symptoms are present, use the disengaging

procedure before proceeding.

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OPERATION

Break-In Period

The break-in period for your new 4-cycle Polaris ATV is defined as the

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

tanks of gasoline. No single action on your part is as important as

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

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

the engine. Perform the following procedures carefully.

CAUTION

Excessive heat build-up during the first three hours of

operation will damage close-fitted engine parts. Do not operate

at full throttle or high speeds for extended periods during the

first three hours of use.

Use of any oils other than those recommended by Polaris may

cause serious engine damage. We recommend the use of

Polaris Premium 4 Synthetic Oil for your 4-cycle engine.

1. Fill the fuel tank with

ADD 8 OZ.

NORMAL

FULL

gasoline (see page 44).

2. Check the oil level on

the dipstick (see page

79). Add the

recommended oil as needed to maintain the oil level in the normal

operating range (1).

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

familiarize yourself with vehicle operation and handling.

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

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

on the daily pre-ride inspection checklist. See page 50.

6. Pull only light loads.

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

hours or 200 miles.

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OPERATION

Pre-Ride Inspection

WARNING

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

injury or death could result. Always inspect the vehicle before

each use to ensure it’s in proper operating condition.

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

working condition before each use.

Item/Inspection Procedure

1. Tires - Check condition and pressures.

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

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

auxiliary brake).

4. Throttle - Check for free operation and closing.

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

lights and switches.

6. Engine stop switch - Check for proper function.

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

that axle nuts are secured by cotter pins.

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

adjustment section); lubricate when needed.

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

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

in any area.

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

or loose nuts/bolts or fasteners.

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

13. Engine coolant - Check for proper level at the recovery bottle.

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OPERATION

Starting the Engine

Starting a Cold Engine

WARNING

Engine exhaust contains poisonous carbon monoxide and can

cause loss of consciousness resulting in severe injury or death.

Never run an engine in an enclosed area.

CAUTION

Operating the vehicle immediately after starting could cause

engine damage. Allow the engine to warm up for several

minutes before operating the vehicle.

1. Place the transmission in neutral

and lock the parking brake.

Make sure the fuel tank valve is

on.

2. Sit on the vehicle and pull the

choke knob out until it stops (1).

NOTE: If the knob doesn’t stay

where positioned, increase the

tension by rotating the tension

adjusting nut (2) clockwise.

NOTE: The variable choke is fully on

when the knob is pulled completely out.

The choke is off when the knob is pushed

completely in. The choke can be

adjusted gradually, depending on how

much choke is needed for starting. Be

sure the choke is off during operation, as

excess fuel washing into the engine oil

will increase wear on engine

components.

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OPERATION

Starting the Engine

Starting a Cold Engine

3. Move the engine stop switch to RUN. NOTE: Do not press the

throttle while starting the engine.

4. 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. If the engine does not start, release the

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

five seconds. Repeat this procedure until the engine starts.

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

allow proper engine warm up.

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

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

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OPERATION

Starting the Engine

Starting a Warm Engine

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

use of the choke can cause the spark plug to become wet fouled.

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

neutral.

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

vehicle, and turn the engine stop switch to RUN.

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

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

necessary.

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

fully while cranking to aid in starting.

5. Release the throttle lever immediately after the engine starts. If the

engine does not start and all conditions are favorable, change the

spark plug and try again.

Cold Weather Operation for 4-Cycle Engines

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

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

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

and must be drained. Water accumulation increases as outside

temperature decreases.

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

warm-ups and easier starting in colder weather.

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OPERATION

Hauling Cargo

2/3

1/3

WARNING

Hauling cargo improperly can alter vehicle handling and may

cause loss of control or brake instability and result in serious

injury or death. Always follow the procedures and precautions

outlined in this owner’s manual and on safety decals when

hauling cargo.

Accessory racks and hitches are available from your Polaris dealer.

Always read and understand the load distribution warnings on all

warning labels, and never exceed the specified weight capacities for the

vehicle.

Maximum Towing Capacities

Refer to the specifications at the rear of this manual for towing

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

the amount of trailer tongue weight.

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

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OPERATION

Hauling Cargo

Procedures and Precautions

S REDUCE SPEED AND ALLOW GREATER DISTANCE FOR

BRAKING WHEN HAULING CARGO.

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

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

reduce speed and cargo to maintain stable driving conditions. Carry-

ing loads on only one rack increases the possibility of vehicle over-

turn.

S LOADS MUST BE CARRIED AS LOW ON THE RACKS AS

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

gravity of the vehicle and creates a less stable operating condition.

When cargo loads are carried high on the racks, the weight of the

loads must be reduced to maintain stable operating conditions.

S ALL LOADS MUST BE SECURED BEFORE OPERATING. Un-

secured loads can create unstable operating conditions, which could

result in loss of control of the vehicle.

S OPERATE ONLY WITH STABLE AND SAFELY ARRANGED

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

securely fasten load and operate with extra caution. Always attach

the tow load to the hitch point designated for your vehicle.

S HEAVY LOADS CAN CAUSE BRAKING AND CONTROL

PROBLEMS. Use extreme caution when applying brakes with a

loaded vehicle. Avoid terrain or situations that may require backing

downhill.

S EXTREME CAUTION MUST BE USED when operating with

loads extending over the rack sides. Stability and maneuverability

may be adversely affected, causing the machine to overturn.

S DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carry-

ing loads on the front rack.

S DO NOT TRAVEL FASTER THAN THE RECOMMENDED

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

ing a load on a level grass surface. Vehicle speed should never ex-

ceed 5 mph (8 kph) when towing loads in rough terrain, while

cornering, or while ascending or descending a hill.

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OPERATION

Driving Safely

Driving Procedures

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

handlebars.

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

transmission into gear.

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

4. Release the parking brake.

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

driving. Vehicle speed is controlled by the amount of throttle

opening.

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

brakes on level surfaces.

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OPERATION

Driving Safely

Making Turns

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

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

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

when turning and the inside tire must slip traction slightly.

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

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

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

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

technique should be used for turning in reverse.

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

at faster speeds.

WARNING

Turning at sharp angles or at excessive speeds can result in

vehicle overturn and lead to serious injury. Avoid turning at

sharp angles. Never turn at high speeds.

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OPERATION

Driving Safely

Driving on Slippery Surfaces

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

or during freezing weather, follow these precautions:

1. Slow down when entering slippery areas.

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

quick, sharp turns which can cause skids.

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

and shifting your body weight forward.

4. Driving with AWD engaged can assist in controlling the vehicle in

slippery areas.

CAUTION

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

engaged while the wheels are spinning.

WARNING

Failure to exercise care when operating on slippery surfaces can

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

and serious injury or death.

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

excessively slippery surfaces. Always reduce speed and use

additional caution.

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OPERATION

Driving Safely

Sidehilling

WARNING

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

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

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

procedures as outlined in the owner’s manual.

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

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

necessary, follow these precautions:

1. Slow down.

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

while keeping your feet on the footrests.

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

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

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

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OPERATION

Driving Safely

Driving Uphill

25_

Maximum

WARNING

Braking and handling are greatly affected when operating in hilly

terrain. Improper procedure could cause loss of control or

overturn and result in serious injury or death.

Avoid climbing steep hills (25_ maximum).

Use extreme caution when operating on hills, and follow proper

operating procedures outlined in the owner’s manual.

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OPERATION

Driving Safely

Driving Uphill

Whenever traveling uphill, follow these precautions:

1. Always travel straight uphill.

2. Avoid steep hills (25_ maximum).

3. Keep both feet on the footrests.

4. Transfer your weight forward.

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

6. Remain alert and be prepared to take emergency action.

This may include quick dismounting of the vehicle.

If all forward speed is lost:

Keep your weight uphill.

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

auxiliary brake as well, then lock the park brake.

If the ATV begins rolling backwards:

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

auxiliary rear brake while rolling backwards.

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

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

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

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

described on page 63.

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OPERATION

Driving Safely

Driving Downhill

Whenever descending a hill, follow these precautions:

1. Proceed directly downhill.

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

3. Slow down.

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

lever.

NOTE: Familiarize yourself with operation of the auxiliary rear brake

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

WARNING

Excessive speed can cause loss of control and lead to serious

injury or death. Always operate slowly when traveling downhill.

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OPERATION

Driving Safely

Turning Around on a Hill

WARNING

Improper hill climbing procedures could cause loss of control or

overturn and result in serious injury or death. Avoid climbing

steep hills (25_ maximum). Use extreme caution when operating

on hills, and follow proper operating procedures outlined in the

owner’s manual.

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

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

while climbing a hill is the K-turn:

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

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

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

vehicle is pointing straight uphill.

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

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

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

pointing across the hill or slightly downward.

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

side, keeping body weight uphill.

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

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

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

8’

Uphill

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OPERATION

Driving Safely

Driving Through Water

Your ATV can operate through water

with a maximum recommended

depth equal to the bottom of

the footrests (1). Follow

these procedures when

operating through water:

1. Determine water

depths and current

before crossing.

2. Choose a crossing where

both banks have gradual inclines.

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

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

lever until braking action is normal.

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

outlined in the maintenance chart. See page 69. The following areas

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

gearcases, and all grease fittings.

CAUTION

Major engine damage can result if the vehicle is not thoroughly

inspected after operation in water. Perform the services outlined

in the maintenance chart.

If your vehicle becomes immersed or is operated in water that

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

before starting the engine.

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

water. If you cannot avoid water that exceeds the recommended

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

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

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

changes.

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

dealer before starting it, follow the steps described on page 102. Have

the vehicle serviced by your dealer at the first opportunity.

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OPERATION

Driving Safely

Driving Over Obstacles

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

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

branches.

WARNING

Severe injury or death can result if your vehicle comes in

contact with a hidden obstacle. Not all obstacles are

immediately visible. Travel with caution in unfamiliar terrain.

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OPERATION

Driving Safely

Driving in Reverse

Follow these precautions

when operating in reverse:

1. Always avoid backing

downhill.

2. Back slowly.

3. When in reverse,

apply the brakes

lightly for stopping.

4. Avoid turning at sharp

angles in reverse.

5. Never open the throttle

suddenly while backing.

WARNING

Failure to use caution when operating in reverse can result in

serious injury or death. Before shifting into reverse, always

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

safe to proceed, back slowly.

Do not use the override switch unless additional power is

required for vehicle movement. Use with caution.

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

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

The override button should be used with caution as rearward vehicle

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

the throttle just enough to maintain a desired speed.

CAUTION

Excessive throttle operation while in the speed limit mode may

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

and/or engine damage.

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OPERATION

Driving Safely

Parking on an Incline

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

these precautions:

1. Turn the engine off.

1. Place the transmission in gear.

2. Set the parking brake.

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

illustration.

4. Shut off the fuel supply.

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EMISSION CONTROL SYSTEMS

Noise Emission Control System

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

may affect compliance with state and local noise level requirements.

Spark Arrestor

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

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

Federal law requires that this spark arrestor be installed and functional

when the vehicle is operated on public lands.

Crankcase Emission Control System

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

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

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

Exhaust Emission Control System

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

design, including factory-set carburetion and ignition. The engine and

related components must be maintained at Polaris specifications to

achieve optimal performance.

Adjustment to engine idle is the

only adjustment Polaris

recommends that the operator

perform. Any other adjustments

should be performed by an

authorized Polaris dealer.

The emissions label (1) is located

on the recoil cover.

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MAINTENANCE AND LUBRICATION

Accessories

Auxiliary power outlets provide 12V power for operating accessories

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

models. Contact your Polaris dealer for more information.

Polaris has a wide range of additional accessories available for your

ATV. See your Polaris dealer.

Periodic Maintenance Schedule

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

most reliable condition. Inspection, adjustment and lubrication of

important components are explained in the periodic maintenance

schedule.

Maintenance intervals in the following charts are based upon average

riding conditions and an average vehicle speed of approximately 10

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

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

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

inspection reveals the need for replacement parts, use genuine Polaris

parts available from your Polaris dealer.

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

with safe service and adjustment procedures, have a qualified dealer

perform these operations.

Maintenance Chart Key

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

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

grease fittings and other critical components.

L Emission Control System Service (California - 4-Cycle)

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

only emissions warranty.

Dealer service item.

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

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

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

Perform all services at whichever reading is reached first.

WARNING

Improperly performing the procedures marked with a J could

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

Have an authorized Polaris dealer perform these services.

Item

Hours/

Miles

Frequency Remarks

Brake System

Auxiliary Brake

Tires

Pre-Ride Pre-Ride

Inspect

Wheels

Frame nuts, bolts,

fasteners

Air filter,

Pre-Ride Pre-Ride

Inspect; clean

Pre-cleaner

Coolant level

Replace coolant every two

years

Fuel and oil tanks

Throttle

Pre-Ride Pre-Ride

Fill to proper levels

Check operation

Lights

Check operation

Engine stop switch Pre-Ride Pre-Ride

Check operation

Drive chain

Steering

Pre-Ride Pre-Ride

Check condition/slack

Check for free operation

Air box sediment

tube

Drain deposits whenever

visible

Headlamp

Pre-Ride Pre-Ride

Check operation daily; ap-

ply Polaris dielectric grease

to connector when replaced

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item

Hours/

Miles

Frequency Remarks

Taillight/brakelight

Pre-Ride Pre-Ride

Check operation daily; ap-

ply Polaris dielectric grease

to socket when replaced

Air filter,

Weekly

20 hrs.

Weekly

Monthly

Inspect; replace as needed

main element

Transmission oil

Inspect level monthly;

change annually

Battery

20 hrs.

Monthly

Check terminals; clean

Engine breather

filter

Inspect; replace annually

and as needed

Brake pad wear

10 hrs.

Monthly

Inspect periodically

Front and rear

gearcase oil

100 hrs. Monthly

Check monthly; change

annually

Engine cylinder

head and cylinder

base fasteners

25 hrs.

3 months

Inspect (re-torque required

at first service only)

General lubrication 50 hrs.

Lubricate all fittings, pivots,

cables, etc.

Engine oil level/oil

change

100 hrs./ 6 months

1000 mi.

Check level daily; break-in

service at one month;

change oil more often in

cold weather

Oil filter

100 hrs./ 6 months

1000 mi.

Replace with oil change

Engine breather

hose

100 hrs. 6 months

Inspect

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

L Emission Control System Service (California)

J Dealer service item

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

WARNING

Improperly performing the procedures marked with a J could

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

Have an authorized Polaris dealer perform these services.

Item

Hours/

Miles

Frequency Remarks

Carburetor float

bowl

50 hrs.

6 months

Drain bowl periodically and

prior to storage

Throttle Cable/ETC 50 hrs.

Switch

Inspect; adjust; lubricate;

replace if necessary

Choke (enricher)

cable

50 hrs.

Inspect; adjust; lubricate;

replace if necessary

Coolant strength/

pressure test sys-

tem

100 hrs. 6 months

Inspect strength seasonal-

ly; pressure test system

annually

Front hubs/fluid

check (AWD)

50 hrs.

6 months

Check monthly

Shift linkage

Drive belt

50 hrs.

6 months

Inspect; adjust

Inspect; replace as needed

Inspect daily; lubricate

Steering

Front suspension

Inspect; lubricate; tighten

fasteners

Rear suspension

Drive chain(s)

50 hrs.

6 months

Inspect; tighten fasteners

Inspect daily; adjust and lu-

bricate if needed

Rear axle

50 hrs

6 months

Inspect bearings

Spark plug

100 hrs. 12 months Inspect; replace as needed

100 hrs. 12 months Inspect; adjust as needed

Ignition Timing

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item

Hours/

Miles

Frequency Remarks

Fuel system

100 hrs. 12 months Check for leaks at tank

cap, lines, fuel valve, filter,

pump and carburetor; re-

place lines every two years

Fuel filter

Radiator

100 hrs. 12 months Replace annually

100 hrs. 12 months Inspect; clean external sur-

face

Cooling system

hoses

100 hrs. 12 months Inspect

Front hubs (AWD)

100 hrs. 12 months Change fluid annually

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

driven)

Engine mounts

Valve clearance

100 hrs. 12 months Inspect

100 hrs. 12 months Inspect; adjust

Brake fluid

200 hrs. 24 months Change every two years

300 hrs. 36 months Clean out

As required Adjust

Spark arrestor

Idle speed

Recoil housing

Toe adjustment

Headlight aim

As required Drain moisture out after rid-

ing in water

As required Periodic inspection; adjust

when parts are replaced

As required Adjust as needed

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

L Emission Control System Service (California)

J Dealer service item

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

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

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

all services at whichever reading is reached first.

Lubrication Chart Key

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

L Polaris Premium All Season Grease or grease conforming to NLG

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

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

periods of storage, or after pressure washing or submerging

When suspension action becomes stiff, or after washing

∆

Item

Lube

Method

Frequency

4-Cycle

Engine

Premium 4

Add to proper level on dip-

Check level daily

Synthetic 0W40 stick.

Brakes

DOT 3 fluid only Maintain level between fill

lines. See page 41.

As required;

change every two

years or 200

hours

Drive chain(s)

O-ring chain

lube or SAE

80/90

Lubricate.

As needed, before

each use in wet

conditions

(1) Transmission

AGL Synthetic

Gearcase Lube

See Page 82.

See Page 83.

Grease fittings.

Change annually

or at 100 hours

(2) Front

Gearcase

Angle Drive

Fluid

Change annually

or at 100 hours

(3) Front Prop

Shaft U-joints

FGrease

3 months/50

hours

(4) Front Prop

Shaft Yoke

Grease fittings

(3 pumps maximum).

3 months/50

hours

(5) Front Drive

Axle (U Joint)

Locate grease fitting and

grease with grease gun.

Every 3 months or

50 hours

(6) Swing Arm

Bushings

Locate fittings on swing arm Monthly or at 20

and grease with grease gun. hours

"L Grease

(7) Tie Rod Ends

Lift boot, clean away dirt and Semi-annually

grease, apply fresh grease

by hand and reassemble.

"L∆ Grease

(8) Front Hubs

Premium

Hub Lube

Remove set screw in hubs.

Rotate wheels to 4 O’clock

position. If lubricant is not

visible add more. Reinstall

set screw.

Annually or at 100

hrs.

(9) Ball Joint

(10) A-Arms

Locate fitting on back side of Every 3 months or

"L Grease

struts and grease with

grease gun.

50 hours

Locate fittings and grease.

Semi-annually

"L∆ Grease

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

(2)

(3)

(1)

(4)

(5)

(7)

(6)

(10)

(8)

4 or 8 o’clock

position- (end view)

(9)

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Record

Use the following chart to record periodic maintenance.

Maintenance

Interval

Performed

Servicing Servicing

Remarks

Date

Dealer

or Person

10 hrs.

20 hrs.

50 hrs.

100 hrs.

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Record

Use the following chart to record periodic maintenance.

Maintenance

Interval

Performed

Servicing Servicing

Remarks

Date

Dealer

or Person

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Premium 4 Synthetic Oil

Polaris Premium 4 All Season Synthetic engine oil has been specially

formulated for use in Polaris 4-cycle engines. It’s a fully synthetic,

high performance, multi-viscosity oil designed to provide the ultimate

in lubrication performance and protection. See page 117 for the part

numbers of Polaris products.

Premium 4 possesses unsurpassed film strength over the widest

possible temperature range. It resists viscosity and frictional

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

exceptional frictional properties result in more efficient operation, more

power output and lower fuel consumption.

Although Polaris Premium 4 is the only oil recommended for use in

this engine, use of any API certified “SH” oil is allowable as long as

it’s 0W-40. Oil may need to be changed more frequently if Polaris

Premium 4 is not used. Follow the manufacturer’s recommendations

for ambient temperature operation.

CAUTION

Mixing brands or using a non-recommended oil may cause

serious engine damage. We recommend the use of Polaris

Premium 4 All Season synthetic oil or API certified “SH” oil,

0W-40. Never substitute or mix oil brands.

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Engine Oil Check

1. Position the machine on a level surface.

2. Start the engine and let it idle for 20-30 seconds, then stop the

engine.

3. Remove the dipstick (1),

which is located on the left

side of the vehicle.

4. Wipe the dipstick dry with a

clean cloth. Reinstall it and

screw it completely in.

NOTE: The dipstick must

be screwed completely in to

keep the angle and depth of

the stick consistent.

5. Remove the dipstick and

read the oil level.

Maintain the oil level in

ADD 8 OZ.

NORMAL

FULL

the normal operating

range (2). Do not overfill.

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

CAUTION

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

hot oil to come into contact with skin.

Oil and Filter Change

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

every six months, whichever comes first.

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

whichever comes first. Severe use operation requires more frequent

service. Severe use includes continuous duty in dusty or wet

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

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

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

Always change the oil filter whenever changing oil.

1. Position the vehicle on a level

surface.

2. Clean the area around the drain

plug (A), which is located on the

bottom of the oil tank.

3. Run the engine for two to three

minutes until warm, then turn the

engine off.

4. Place a drain pan beneath the

vehicle and remove the drain plug.

5. Allow the oil to drain completely.

6. Install a new sealing washer (B)

on the oil drain plug. NOTE:

The sealing surfaces on the drain

plug and on the oil tank should be clean and free of burrs, nicks or

scratches.

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

8. Disconnect the lower oil delivery hose. Remove the fitting (C)

from the oil tank. Clean the fitting screen. Reinstall the fitting

screen, torquing to 14-17 ft. lbs. (19-23 Nm). Reattach the oil line

and torque the hose clamp (D) to 25 in. lbs. (2.8 Nm).

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Oil and Filter Change

9. Place shop towels beneath the

oil filter (1). Using an oil filter

wrench, turn the filter

counterclockwise to remove.

10. Using a clean, dry cloth, clean

the filter sealing surface on the

crankcase.

11. Lubricate the gasket on the new

filter with a film of new engine

oil. Make sure the gasket is in

good condition. Also make sure the gasket from the old filter is

not still on the engine.

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

gasket contacts the engine.

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

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

the crankcase. Reinstall the drain plug after draining.

NOTE: The sealing surfaces on the drain plug and crankcase

should be clean and free of burrs, nicks or scratches.

CAUTION

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

extremely important to drain, refill and start the engine in an

expedient manner. Do not allow the engine to sit without oil

for extended periods.

14. Remove the dipstick (2) and add the recommended oil. NOTE: If

the sump is not drained, add about 1 3/4 quarts (1.66 l) initially.

15. Reinstall the dipstick.

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

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

engine and inspect for leaks.

18. Re-check the oil level on the dipstick and add oil as necessary to

bring the level to the upper mark on the dipstick.

19. Dispose of used filter and oil properly.

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Transmission Oil Check

The transmission lubricant level should be checked every six months or

1000 miles (1600 km), whichever comes first. Maintain the oil level at

the bottom of the fill hole threads. Change transmission oil annually.

We recommend the use of AGL Synthetic Gearcase Lubricant. See

page 117 for the part numbers of Polaris products.

1. Position the ATV on a level

surface and remove the fill plug (1),

which is located on the right side

of the machine, behind the

propshaft shield.

2. Add the recommended lubricant as

needed to maintain the oil level at

the bottom of the fill hole threads.

3. Reinstall the fill plug.

Transmission Oil Change

1. Remove the propshaft shield from the right side of the vehicle to

access the fill plug. Remove the fill plug.

2. Remove the transmission drain plug located on the bottom

left-hand side and drain the oil into an appropriate container.

Discard used oil properly.

3. Clean and reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm).

4. Add the proper amount of the recommended lubricant. Refer to the

specifications section beginning on page 114 for capacities.

5. Reinstall the fill plug and check for leaks.

6. Reinstall the propshaft shield.

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Front Gearcase Oil Check

The front gearcase oil level should be checked every six months or

1000 miles (1600 km), whichever comes first. Maintain the oil level at

the bottom of the fill plug threads. Change the oil annually. We

recommend the use of Polaris Angle

Drive Fluid. See page 117 for the part

numbers of Polaris products.

1. Position the ATV on a level

surface.

2. Remove the fill plug (1) and check

the oil level.

3. Add the recommended oil as

needed to maintain the level at the

bottom of the fill plug threads.

4. Reinstall the fill plug.

Front Gearcase Oil Change

1. Position the vehicle on a level surface and remove the fill plug.

2. Place a drain pan beneath the gearcase, remove the gearcase drain

plug, and drain the oil.

3. Clean and reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm).

4. Add 4 oz. (120 ml) of the recommended gearcase oil.

5. Reinstall the fill plug and check for leaks.

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Drive Chain

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

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

be lubricated.

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

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

slack adjustment. Maintain the stone guard to rear sprocket clearance

at 1/8″ (.3 cm).

Regularly lubricate the drive chain with Polaris Chain Lube, an SAE

80-90 lube or an approved o-ring chain spray lube. See page 117 for the

part numbers of Polaris products.

CAUTION

Washing the drive chain with a high pressure washer or gasoline

can cause damage to the o-rings, causing premature wear and

drive chain failure. Do not use a high pressure washer or

gasoline to clean the drive chain.

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MAINTENANCE AND LUBRICATION

Adjustments

WARNING

Severe injury or death can result from improper toe alignment and

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

adjustments should be performed by an authorized Polaris dealer.

Toe Alignment

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

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

1. Set the handlebars in a

straight-ahead position.

NOTE: The steering frog

can be used as an indicator

of whether the handlebars are

straight. The frog should

always point straight back

from the steering post.

2. Place stands (1) in front of

the vehicle, perpendicular to

the rear tires. See

illustration.

3. Tie an elastic string around

the stands, making sure the

string just touches the side

surface of the rear tires on

each side of the vehicle and

goes around the stands in

front of the vehicle (2).

4. Measure the distance from

the string to the rim at the

front and rear of the front

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

more than the front measurement.

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

for service.

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MAINTENANCE AND LUBRICATION

Adjustments

Brakes

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

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

self-adjusting.

The following checks are recommended to keep the brake system in

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

under normal operation, such as in hilly country or in muddy terrain.

WARNING

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

hygroscopic, meaning it rapidly absorbs moisture from the air.

The moisture causes the boiling temperature of the brake fluid to

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

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

always discard any unused portion.

1. Always maintain brake fluid at an adequate level (see page 41).

WARNING

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

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

brake fluid at the recommended level. Do not overfill.

NOTE: Under normal operation, the diaphragm extends into the

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

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

be replaced. Always fill the reservoir as needed whenever the cover is

loosened or removed to ensure proper diaphragm operation. Use

Polaris DOT 3 brake fluid. Do not overfill.

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MAINTENANCE AND LUBRICATION

Adjustments

Brakes

1. Check the brake system for fluid leaks.

2. Check the brakes for excessive travel or

spongy feel.

3. Check the friction pads for wear,

damage and looseness.

4. Check the security and surface

condition of the disc.

NOTE: Pads should be changed when

worn to 3/64″ (.1 cm), or about the

thickness of a U.S. dime.

3/64″ (.1 cm)

Auxiliary Brake

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

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

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

footrest. The hydraulic auxiliary brake system requires no adjustment.

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

all-wheel single lever system.

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MAINTENANCE AND LUBRICATION

Adjustments

Steering Assembly

The steering assembly of the ATV should be checked periodically for

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

dealer for service before operating the vehicle.

Camber and Caster

The camber and caster are non-adjustable.

Rear Spring

The rear shock absorber spring is

adjusted by rotating the adjuster (1)

either clockwise or counterclockwise

to increase or decrease spring

tension.

NOTE: Accessory springs are

available through your Polaris dealer.

Throttle Cable Freeplay

Throttle cable freeplay is adjusted at the handlebar.

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

the adjuster locknut (3).

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

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

throttle lever back and forth.

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

they touch at the midpoint of the adjuster.

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MAINTENANCE AND LUBRICATION

Adjustments

WARNING

Improper adjustment of the handlebars or incorrect torquing of

the adjuster block tightening bolts can cause limited steering or

loosening of the handlebars, resulting in loss of control and

possible serious personal injury or death. Follow the adjustment

procedures exactly, or see your Polaris dealer for service.

Handlebars

The handlebars can be adjusted for

rider preference.

1. Remove the handlebar cover to

access the handlebar bolts (1).

2. Loosen the four bolts.

3. Adjust the handlebar to the

desired height. Be sure the

handlebars do not contact the

gas tank or any other part of the

machine when turned fully to

the left or right.

4. Torque the two front bolts to 10-12 ft. lbs. (14-17 Nm), then

torque the two rear bolts. A gap of up to 1/8” will remain at the

rear bolts.

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MAINTENANCE AND LUBRICATION

Adjustments

Carburetor

IMPORTANT: Your Polaris ATV is calibrated at the factory for

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

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

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

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

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

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

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

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

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

NOTE: Continuous operation of the engine without proper jetting

when required can cause poor performance, overheating and engine or

PVT damage. See your Polaris dealer for more information about

jetting the ATV for conditions in your area.

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

favorable, the carburetor can be adjusted.

1. Warm up the engine by running the

vehicle for approximately five minutes.

2. Place the transmission in gear and engage

the parking brake.

3. Adjust the carburetor idle screw (1) either

in or out until the desired idle RPM is

reached. Refer to the specifications

section beginning on page 114 for the

proper setting.

NOTE: Turn the screw in (clockwise) to

raise RPM. Turn the screw out

(counterclockwise) to lower RPM.

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MAINTENANCE AND LUBRICATION

Adjustments

WARNING

Operating your ATV with worn tires, improperly inflated

tires, non-standard tires or improperly installed tires will

affect vehicle handling and could cause an accident

resulting in serious injury or death.

Maintain proper tire pressure as described on the decal on

your ATV and in your owner’s manual.

Always use original equipment size and type when

replacing tires.

Make sure the wheels are installed properly.

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

(.3 cm) or less.

Wheel Removal

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

parking brake.

2. Loosen the wheel nuts slightly.

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

footrest frame.

4. Remove the wheel nuts and remove the wheel.

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MAINTENANCE AND LUBRICATION

Adjustments

Wheel Installation

1. Make sure the transmission is in

gear with the parking brake

locked.

2. Place the wheel on the wheel

hub with the valve stem toward

the outside and the rotation

arrows on the tire pointing

toward forward rotation.

3. Install the wheel nuts and finger

tighten.

4. Lower the vehicle to the ground.

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

specifications chart.

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

authorized Polaris dealer.

Wheel Nut Torque Specifications

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

loosened for maintenance service.

Bolt Size

Front 3/8″

Rear 3/8″

Rear 1/2″

Specification

20 ft. lbs. (27 Nm)

50 ft. lbs. (68 Nm)

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MAINTENANCE AND LUBRICATION

Adjustments

Front Wheel Hub Tightening

Front wheel bearing tightness and spindle nut retention are critical

component operations. All service must be performed by your

authorized Polaris dealer.

Tire Tread Depth

Always replace tires when tread

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

See illustration.

1/8I (.3 cm)

WARNING

Operating the vehicle with worn tires will increase the

possibility of skidding, which could lead to loss of control and

serious injury or death. Always replace tires when the tread

depth measures 1/8″ (.3 cm) or less.

WARNING

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

inflation may adversely affect vehicle maneuverability and cause

loss of control resulting in serious injury or death. Maintain

proper tire pressure as outlined in this owner’s manual. When

replacing a tire always use original equipment size and type.

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MAINTENANCE AND LUBRICATION

Adjustments

Rear Drive Chain Slack

CAUTION

Adjusting or operating the ATV with improper rear drive chain

slack can result in severe damage to the transmission and drive

components. Always make sure the slack is within the stated

specifications.

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

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

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

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

deflection. Use the following procedure if adjustment is required.

3/16″-3/8″ (.48 cm - .95 cm)

1. Remove the chain guard if

applicable.

2. Loosen the chain guide.

3. Loosen the two eccentric

locking bolts (1).

4. Loosen the caliper mounting

bracket bolt located on the

side of the swing arm.

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

eccentric housing.

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MAINTENANCE AND LUBRICATION

Adjustments

Rear Drive Chain Slack

6. Roll the ATV forward or backward

to adjust the chain slack to the

proper tension. See the illustration

for proper splice link clip opening

position (1).

7. Tighten the eccentric locking bolts

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

without the hitch and 45 ft. lbs. (61

Nm) for machines with a hitch.

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

9. Remove the pin punch.

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

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

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

deflection.

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

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

12. Reinstall the chain guard if applicable.

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MAINTENANCE AND LUBRICATION

Engine Cooling System

Coolant Level

The recovery bottle (1) is located

on the left side of the machine.

The fluid level must be maintained

between the minimum and

maximum marks on the bottle

(when the fluid is cool).

The engine coolant level is

controlled or maintained by the

recovery system. The recovery

system components are the

recovery bottle, radiator filler neck, radiator pressure cap and

connecting hose.

As coolant operating temperature increases, the expanding (heated)

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

into the recovery bottle. As engine coolant temperature decreases, the

contracting (cooled) coolant is drawn back up from the tank, past the

pressure cap, and into the radiator.

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

purging itself of trapped air. Observe coolant levels and maintain as

recommended by adding coolant to the recovery bottle.

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

recommend that the system be completely drained every two years and

a fresh mixture of antifreeze and water added.

Polaris recommends the use of Polaris Premium 60/40

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

compatible anti-freeze/coolant and distilled water. See page 117 for the

part numbers of Polaris products.

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

Do not dilute with water.

NOTE: Always follow the manufacturer’s mixing recommendations

for the freeze protection required in your area.

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MAINTENANCE AND LUBRICATION

Engine Cooling System

WARNING

Escaping steam can cause severe burns. Never remove the

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

engine to cool before removing the pressure cap.

Radiator Coolant Level

NOTE: This procedure is required only

if the cooling system has been drained

for maintenance and/or repair. However,

if the recovery bottle has run dry, the

level in the radiator should be inspected

and coolant added if necessary.

1. Remove the front panel to access the

radiator pressure cap (1). Remove

the cap.

2. If coolant is low, use a funnel and

slowly add coolant through the

radiator filler neck.

3. Reinstall the pressure cap and secure the front panel.

4. Fill the coolant recovery bottle to the upper mark on the bottle.

5. Check the coolant level in the bottle frequently, adding coolant as

needed until the level stabilizes.

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

recovery system to function properly. Contact your dealer for the

correct replacement part.

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MAINTENANCE AND LUBRICATION

Lights

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

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

will shorten the life of the lamp.

WARNING

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

Headlight and taillight lenses become dirty during normal operation.

Wash the headlights frequently to maintain lighting quality.

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

the headlamps until they’ve cooled sufficiently.

Headlight Lamp Replacement

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

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

bulb.

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

new bulb. Install the replacement bulb into headlight housing and

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

the harness installs into the lamp at the bottom.

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

High Beam Adjustment

The headlight beam can be adjusted vertically.

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

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

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

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

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

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

the headlight beam should be aimed 2” (5.1 cm) below the mark

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

measuring.

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

6. Tighten the bolt and torque to 60 in. lbs. (7 Nm).

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MAINTENANCE AND LUBRICATION

Lights

Taillight/Brakelight Lamp Replacement

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

replaced.

1. Remove the taillight lens cover

mounting screws. Remove the

lens cover and gasket and set

aside for reassembly.

2. Remove the lamp (1) and

replace it with a new lamp.

3. Test the taillight/brakelight to

see that it’s working.

4. Reinstall the gasket and lens cover.

Indicator Lamp Replacement

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

the indicator panel.

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

1/4 turn counterclockwise.

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

indicator panel housing.

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

5. Reinstall the instrument panel if removed.

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MAINTENANCE AND LUBRICATION

Filter Systems

Air Filter Service

1. Remove the seat, release

the clips, and remove the

air box cover.

2. Loosen the clamp and remove

the filter.

3. Remove the fabric type pre-filter (1)

from the main filter (2). Wash the

pre-filter in soapy water, then rinse

and let dry.

4. Reinstall the pre-filter over the main

filter. (Replace the main filter if needed.)

5. Reinstall the filter into the air box and tighten

the clamp. Do not over tighten the clamp, as filter damage could

occur.

Breather Filter/Hose

CAUTION

Operation of your vehicle without a breather filter can cause

engine damage. Always reinstall the breather filter after

removing for service.

1. Remove the clamps and pull the filter (1)

out of the hoses. NOTE: It’s not

necessary to remove the lower hose

from the engine.

2. Inspect the filter for debris. Blow

gently through the filter in the direction

of the arrow to check for clogging.

Replace if needed.

3. Check the hoses for cracks,

deterioration, abrasion, or leaks. Replace as needed.

4. Reinstall the filter and secure the clamps. NOTE: The filter is

effective with the arrow pointing in either direction.

100

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MAINTENANCE AND LUBRICATION

Spark Plugs

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 114.

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

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

up and the vehicle has been driven at higher speeds. Immediately

check the spark plug for correct color.

WARNING

A hot exhaust system and engine can cause serious burns. Wear

protective gloves when removing a spark plug for inspection.

1. Normal

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

combustion deposits. The electrodes are not burned or eroded. This

indicates the proper type and heat range for the engine and the service.

NOTE: The tip should not be white. A white insulator tip indicates

overheating, caused by use of an improper spark plug or incorrect

carburetion adjustments.

2. Wet Fouled

The wet fouled insulator tip is black. A damp oil film covers the firing

end. There may be a carbon layer over the entire nose. Generally, the

electrodes are not worn. General causes of fouling are excessive oil,

use of non-recommended injection oil, improper use of the choke, or

incorrect carburetion adjustments.

Spark Plug Removal and Replacement

1. Remove the spark plug cap.

2. Using the special wrench provided in the tool pouch, rotate the

spark plug counterclockwise to remove.

3. Reverse the procedure for spark plug installation. Torque to 14 ft.

lbs. (19 Nm).

101

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MAINTENANCE AND LUBRICATION

Vehicle Immersion

CAUTION

If your vehicle becomes immersed, major engine damage can

result if the machine is not thoroughly inspected. Take the

vehicle to your dealer before starting the engine.

If it’s impossible to take your ATV to a dealer before starting it, follow

the steps outlined below.

1. Move the ATV to dry land or at the

very least, to water below the

footrests.

2. Check the airbox for any water. Drain

and dry it if water is present.

3. Turn the fuel valve off.

4. Remove the spark plug.

5. Turn the engine over several times

using the electric start.

6. Loosen the carburetor drain screw (1).

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

8. Tighten the carburetor drain screw.

9. Turn the fuel valve on.

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

procedure.

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

whether you succeed in starting it or not.

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

on page 105 for drying out the PVT.

102

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MAINTENANCE AND LUBRICATION

Recoil Housing

To prevent possible engine damage,

always drain the recoil housing (1)

after operating the ATV in very wet

conditions. This should also be

done before storing the ATV.

Water will enter the recoil housing

if the starter handle is disengaged

from the rope guide when under

water.

The drain screw is located at the

bottom of the recoil housing. Use a

wrench to remove the screw. Be sure to reinstall the screw after

draining the housing.

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

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

crankcase drain is opened.

103

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MAINTENANCE AND LUBRICATION

PVT System

The basic operation of the Polaris PVT system is dependent on engine

speed and vehicle torque requirements. As engine speed increases, the

force exerted on the movable drive sheave by the flyweights also

increases. This, in turn, increases the amount of “pinch” applied to the

drive belt. Similarly, if the engine speed decreases, the amount of

centrifugal force decreases, reducing the amount of belt “pinch.” This

begins to occur at speeds of less than 5 MPH, due to the system’s

dependence on engine speed.

For example, when operating at a ground speed of 3 MPH, the engine

would be running at only about 1500 RPM, with an engagement speed

of about 1400 RPM. Whenever operating this close to the engagement

point, the engine may be running at a speed too low to provide the

adequate “pinch” needed to prevent incomplete engagement.

Incomplete engagement creates excessive heat that can destroy belts

and clutch covers. In some cases, excessive clutch wear and damage

may result.

If the ATV will be operated for extended periods below 5 MPH, or for

towing loads, we recommend that you install a one tooth smaller

counter shaft sprocket to raise the operating RPM far enough above the

engagement RPM to reduce heat caused by incomplete engagement.

Reducing the temperature inside the clutch cover extends the life of the

PVT components (belt, cover, etc.).

NOTE: Avoid heavy pulling and extended low-speed operation.

104

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MAINTENANCE AND LUBRICATION

PVT System

WARNING

Failure to comply with the instructions in this warning can result

in severe injury or death.

Do not modify any component of the PVT system. Doing so may

reduce its strength so that a failure may occur at a high speed.

The PVT system has been precision balanced. Any modification

will cause the system to be out of balance, creating vibration and

additional loads on components.

The PVT system rotates at high speeds, creating large amounts

of force on clutch components. Extensive engineering and

testing has been conducted to ensure the safety of this product.

However, as the owner, you have the following responsibilities to

make sure this system remains safe:

Always follow all recommended maintenance procedures. See

your dealer as outlined in the owner’s manual.

This PVT system is intended for use on Polaris products only. Do

not install it in any other product.

Always make sure the PVT housing is securely in place during

operation.

PVT Drying

There may be some instances when water is accidently ingested into

the PVT system. Use the following instructions to dry it out before

operating:

1. Remove the drain plug and allow the water to drain. Reinstall the

drain plug.

2. Start the engine and shift the transmission into neutral. Apply

varying throttle for 10-15 seconds to expel the moisture and air-dry

the belt and clutches. Do not hold the throttle wide open for more

than 10 seconds.

3. Allow the engine RPM to settle to idle speed, then shift the

transmission to the lowest available range.

4. Test for belt slippage. If the belt slips, repeat the process.

5. Take the vehicle to your dealer for service as soon as possible.

105

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MAINTENANCE AND LUBRICATION

Spark Arrestor

WARNING

Failure to heed the following warnings while servicing the spark

arrestor could result in serious injury or death.

Do not perform service on the spark arrestor while the system is

hot. Exhaust system temperatures can reach 1000° F. Allow

components to cool sufficiently before proceeding.

Remove any combustible materials from the area.

Wear eye protection.

Do not stand behind or in front of the vehicle while purging.

Never run the engine in an enclosed area. Exhaust contains

poisonous carbon monoxide gas.

Never go under the vehicle while it’s inclined.

1. Remove the arrestor clean-out

plug (1) from the bottom of the

muffler.

2. Place the transmission in neutral

and start the engine.

3. Purge carbon from the system by

momentarily revving the engine

several times.

4. If carbon is expelled, cover or plug the

exhaust outlet (2) and rap on the pipe around

the cleanout plug while revving the engine several more times.

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

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

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

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

engine is revved.

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

arrestor plug and remove the outlet cover or plug.

106

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MAINTENANCE AND LUBRICATION

WARNING

Battery

Improperly connecting or disconnecting battery cables can result

in an explosion and cause serious injury or death. When removing

the battery, always disconnect the negative (black) cable first.

When reinstalling the battery, always connect the negative (black)

cable last.

Battery Removal

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

remove battery cover.

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

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

4. Lift the battery out of the ATV.

Battery Installation

When installing a new battery, make sure it’s fully charged prior to its

initial use. Using a new battery that has not been fully charged can

damage the battery and result in a shorter life. It can also hinder

vehicle performance. Follow the battery charging instructions on page

108 before installing the battery.

1. Ensure that the battery is fully charged.

2. Set the battery in the battery holder.

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

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

5. Reinstall the battery cover and attach the hold-down strap.

6. Verify that cables are properly routed.

107

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MAINTENANCE AND LUBRICATION

Battery

Battery Storage

When the vehicle is placed in storage for three months or more, the

battery should be removed, stored out of the sun in a cool, dry place

and tested monthly. Before reusing, take the battery to your dealer for

testing and recharging.

Power plug leads may need to be bent down so that the battery cover

can be installed.

Battery Charging

The following battery charging instructions apply only to the

installation of a YUASA activated, sealed battery. Read all

instructions before proceeding with the installation of this battery.

The YUASA activated, sealed battery is already filled with electrolyte

and has been sealed and fully charged at the factory. Do not ever pry

the sealing strip off or add any other fluid to this battery.

The single most important thing to maintaining a sealed battery is to

keep it fully charged. Since the battery is sealed and the sealing strip

cannot be removed, you must use a voltmeter or multimeter to measure

DC voltage.

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 the battery voltage is 12.8 V 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 following guidelines for recharging.

WARNING

An overheated battery could explode, causing severe injury or

death. Always watch charging times carefully. Stop charging if

the battery becomes very warm to the touch. Allow it to cool

before resuming charging.

108

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MAINTENANCE AND LUBRICATION

Battery

Battery Charging

NOTE: Always verify battery condition before and 1-2 hours after the

end of charging.

State of

Charge

Voltage

Action

Charge Time*

(Using constant current

charger @ standard amps

specified on top of battery)

100%

12.8-13.0 volts

12.5-12.8 volts

None, check at

3 mos. from date of

manufacture

None required

75%-100%

May need slight

charge, if no

charge given,

check in 3 months

3-6 hours

50%-75%

25%-50%

12.0-12.5 volts

11.5-12.0 volts

Needs charge

5-11 hours

At least 13 hours,

verify state of charge

0%-25%

11.5 volts or less Needs charge with

desulfating charger

At least 20 hours

109

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MAINTENANCE AND LUBRICATION

Cleaning and Storage

See page 117 for the part numbers of Polaris products.

Cleaning the ATV

Keeping your ATV clean will not only improve its appearance but it

can also extend the life of various components. With a few

precautions, your ATV can be cleaned much like an automobile.

Washing the ATV

The best and safest way to clean your ATV is with a garden hose and a

pail of mild soap and water. Use a professional type washing mitten,

cleaning the upper body first and the lower parts last. Rinse with water

frequently and dry with a chamois to prevent water spots. NOTE: If

warning and safety labels are damaged, contact your a Polaris dealer

for free replacement.

Polaris does not recommend the use of a high pressure type car wash

system for washing the ATV. If a high pressure system is used,

exercise extreme care to avoid water damage to the wheel bearings,

transmission seals, body panels, brakes and warning labels. NOTE:

Grease all zerk fittings immediately after washing, and allow the

vehicle to run for a while to evaporate any water that may have entered

the engine or exhaust system.

Waxing the ATV

Your ATV can be waxed with any non-abrasive automotive paste wax.

Avoid the use of harsh cleaners since they can scratch the body finish.

CAUTION

Certain products, including insect repellants and chemicals,

will damage plastic surfaces. Use caution when using these

products near plastic surfaces.

110

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MAINTENANCE AND LUBRICATION

Cleaning and Storage

Storage Tips

See page 117 for the part numbers of Polaris products.

CAUTION

Starting the engine during the storage period will disturb the

protective film created by fogging and damage could occur.

Never start the engine during the storage period.

Exterior

Make necessary repairs and then clean the ATV thoroughly with mild

soap and warm water to remove all dirt and grime. Don’t use harsh

detergents or high pressure washers. Some detergents deteriorate rubber

parts. Use dish soap type cleaners only. High pressure washers may

force water past seals.

Fuel Stabilizer

Polaris Carbon Clean is a fuel stabilizer and fuel system dryer. It

cleans the fuel system, the combustion chamber and the exhaust ports.

It also prevents bacterial growth and promotes better starting after the

storage period.

1. Fill the fuel tank with fuel and add Polaris Carbon Clean or Fuel

Stabilizer. Follow the instructions on the container for the

recommended amounts.

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

can disperse through the fuel in the tank and carburetor.

3. Stop the engine, turn the fuel valve off, and drain the carburetor bowl.

Oil and Filter

Warm the engine and change the oil and filter.

Air Filter / Air Box

Inspect and clean or replace the pre-cleaner and air filter. Clean the air

box and drain the sediment tube.

Breather Filter(s)

Inspect and clean or replace the breather filter(s).

Recoil Housing

Remove the recoil housing drain plug and drain any moisture.

111

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MAINTENANCE AND LUBRICATION

Cleaning and Storage

Storage Tips

See page 117 for the part numbers of Polaris products.

Fluid Levels

Inspect the following fluid levels and change if necessary: front

gearcase; transmission; front hubs; brake fluid (change every two years

or as required if fluid looks dark or contaminated).

Engine

1. Support the front end of the machine so the engine is level or tilted

slightly rearward.

2. Remove the spark plug.

3. Rotate the piston to BDC and pour approximately two ounces of

Premium 4 Synthetic 4-cycle oil into the cylinder.

4. Reinstall the spark plug.

5. Apply dielectric grease to the inside of the spark plug cap and install

the cap onto the plug.

6. Turn the engine over several times, using the recoil starter, to

ensure coverage of piston rings, cylinder walls and crankshaft

bearings.

7. Treat the fuel system with Polaris Carbon Clean.

8. If Polaris fuel system additive is not used, the fuel tank, fuel lines,

and carburetor should be completely drained of gasoline.

Engine Anti-Freeze

Test engine coolant strength and change if necessary. Replace coolant

every two years.

Lubricate

Inspect all cables and lubricate with Polaris Cable Lubricant. Follow

lubrication guidelines in the maintenance section of the service or

owner’s manual to completely grease and lubricate the entire vehicle

with Polaris Premium All Season Grease. Apply Polaris O-Ring Chain

Lube to the drive chain(s).

Storage Area/Covers

Set the tire pressure and safely support the ATV with the tires 1-2” off

the ground. Be sure the storage area is well ventilated, and cover the

machine with a genuine Polaris ATV cover. NOTE: Do not use plastic

or coated materials. They do not allow enough ventilation to prevent

condensation, and may promote corrosion and oxidation.

112

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MAINTENANCE AND LUBRICATION

Transporting the ATV

Follow these procedures when

transporting the vehicle.

1. Turn off the engine and

remove the key to prevent loss

during transporting.

2. Turn the fuel valve off.

3. Be sure the fuel cap, oil cap

and seat are installed correctly.

4. Always tie the frame of the

ATV to the transporting unit

securely using suitable straps

or rope. See illustration.

5. Always place the transmission

in gear and lock the parking

brake.

113

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SPECIFICATIONS

2004 Scrambler 500 4x4

Capacities

Body Style

Gen III

Gross Vehicle Weight

Fuel

845 lbs. (383 kg)

3.5 gal. (13.2 l)

Transmission Oil

Coolant

Engine Oil

32 oz. (946 ml)

2.25 qts. (2.13 l)

2 qts. (1.89 l)

Front Rack (Accessory)

Rear Rack (Accessory)

Hitch Towing Rating

Hitch Tongue Weight Capacity

30 lbs. (13.6 kg) (Maximum)

60 lbs. (27.2 kg) (Maximum)

850 lbs. (386 kg)

85 lbs. (38.6 kg)

Unbraked Trailer Towing Capacity* 1210 lbs. (549 kg)

Turn Radius

Ground Clearance

Height

Length

Width

Seat Height

Dry Weight

Wheel Base

83 in. (210.8 cm)

5.5 in. (14 cm)

47 in. (119.4 cm)

75 in. (190.5 cm)

46 in. (116.8 cm)

34 in. (86.4 cm)

571 lbs. (259.5 kg)

48 in. (121.9 cm)

Engine & Cooling

Engine Model Number / Type

Lubrication

EH50PLE-123 / 4 Cycle, Single Cylinder

Dry Sump

Bore x Stroke

Displacement

Compression Ratio

Engine Cooling

Alternator Output (watts)

Carburetion

92 x 75

499

10:2

Liquid

250w @5000 rpm

BST 40

Main Jet

155

Pilot Jet

Needle Jet

Pilot Air Jet

Y-0M (896)

160

Pilot Screw

2.0 turns

Jet Needle

6H25-94-3

Ignition

CDI

Timing

Spark Plug Type / Gap

30° ± 2° @ 5000 RPM

BKR6E / .036 in. (.9 mm)

* Based on EU Directive 76/432/EC

114

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SPECIFICATIONS

2004 Scrambler 500 4x4

Drive System

Drive System Type

Shift Type

PVT

Side Lever (F-N-R)

4.74/1

Gear Reduction - Reverse

Gear Reduction - Forward

Front Drive (ratio)

Final Drive (ratio)

Drive Chain

3.06/1

2/1

13/36 76P

520 O-Ring

Front Tires

23 x 7-10 (4 psi)

22 x 11-10 (3 psi)

Suspension and Brakes

8.2 in. (20.8 cm) travel

Rear Tires

Front Suspension: Mac Strut

Rear Suspension: Progressive Rate 10.5 in. (26.7 cm) travel

Swing Arm

Shock Adjustment

Front Brake

CAM

Fixed disc, hydraulic floating caliper

Rear Brake

Hydraulic, opposed piston caliper, rear axle

fixed disc

Auxiliary Brake

Park Brake

Hydraulic, opposed piston caliper, rear axle

fixed disc

Hydraulic lock, all wheel

Features

Headlight

2 Dual Beam 30w/30w

8.26w

Taillight

Brake Light

26.9w

Battery

12V 14 AH

Accessory

Standard

DC Plug-In (Rear)

DC Socket (Forward)

Electric Start

High Beam Indicator

High Temp Indicator

Windshield

Standard

Accessory

Not Applicable

Standard

Low Oil Light

Neutral Indicator

Reverse Indicator

Speedometer

Fuel Gauge

Standard

Accessory

Standard

Tool Kit

Standard

115

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SPECIFICATIONS

2004 Scrambler 500 4x4

Jetting Chart

Altitude

AMBIENT

TEMPERATURE

Below 40° F

(Below 5° C)

+40°F and above

(+5°C and above)

Meters

(Feet)

0-1800

(0-6000)

160

155

1800-3700

(6000-12000)

152.5

147.5

Clutching Chart

Altitude

Shift

Weight

Drive Clutch Driven Clutch

Helix/Spring

Setting

Spring

Meters

(Feet)

0-1800

(0-6000)

10WH

5630710

Blue/Green

7041157

Silver

7041499

40°

5131446

1+1

1800 & above

(6000 & above)

10RH

5630709

Blue/Green

7041157

Silver

7041499

40°

5131446

1+1

116

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POLARIS PRODUCTS

Part No.

Description

Engine Lubricant

2870791

2871281

2871844

2871567

Fogging Oil (12 oz. Aerosol)

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

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

Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (16 gal.)

Gearcase / Transmission Lubricants

AGL Synthetic Gearcase Lubricant (qt.)

AGL Synthetic Gearcase Lubricant (gal.)

AGL Synthetic Gearcase Lubricant (2.5 gal.)

Angle Drive Fluid (8 oz.)

2873602

2873603

2873604

2871653

2872276

2870465

2871654

2872277

Angle Drive Fluid (2.5 gal.)

Oil Pump for Gearcase Oil

Premium Drive Hub Fluid (8 oz.)

Premium Drive Hub Fluid (2.5 gal.)

Grease / Specialized Lubricants

Premium All Season Grease (3 oz. cartridge)

Premium All Season Grease (14 oz. cartridge)

Starter Drive Grease

2871322

2871423

2871460

2871515

2871551

2871312

2871329

2872073

2872348

Premium U-Joint Lube (3 oz.)

Premium U-Joint Lube (14 oz.)

Grease Gun Kit

Dielectric Grease (Nyogelt)

Chain Lube (6.25 oz. aerosol)

Chain Lube (16 oz. aerosol)

Coolant

2871323

2871534

60/40 Coolant (gal.)

60/40 Coolant (qt.)

Additives / Miscellaneous

Disc Brake Quiet, Aerosol (9 oz.)

Carbon Clean Plus (12 oz.)

Fuel Stabilizer (16 oz.)

2872113

2871326

2870652

2870990

2872893

2871956

DOT3 Brake Fluid

Engine Degreaser

Loctitet 565 Thread Sealant

117

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TROUBLESHOOTING

Contact your Polaris dealer for service if you’re unable to identify

solutions using the following charts.

Drive Belt and Cover Problems

Possible Cause

Solution

Driving the ATV onto a

pickup or tall trailer in

high range.

Shift transmission to low range during loading of the ATV

to prevent belt burning.

Starting out going up a

steep incline.

When starting out on an incline, use low range or dis-

mount the ATV (after first applying the park brake) and

perform the K-turn as described on page 63.

Driving at low RPM or

low ground speed (at

Drive at a higher speed or use low range more frequently.

The use of low range is highly recommended for cooler

approximately 3-7 MPH). PVT operating temperatures and longer component life.

Insufficient warm-up of Warm the engine at least 5 minutes. With the transmission

ATVs exposed to low am- in neutral, advance the throttle to about 1/8 throttle in

bient temperatures.

short bursts, 5 to 7 times. The belt will become more flex-

ible and prevent belt burning.

Slow and easy clutch en- Use the throttle quickly and effectively for efficient enga-

gagement.

gement.

Towing/pushing at low

RPM/low ground speed.

Use low range only.

Utility use/plowing snow, Use low range only.

dirt, etc.

Stuck in mud or snow.

Shift the transmission to low range, and carefully use fast,

aggressive throttle application to engage clutch.

WARNING: Excessive throttle may cause loss of control

and vehicle overturn.

Climbing over large ob-

Shift the transmission to low range, and carefully use fast,

jects from a stopped posi- brief, aggressive throttle application to engage clutch.

tion.

WARNING: Excessive throttle may cause loss of control

and vehicle overturn.

Belt slippage from water

Shift the transmission to neutral. Using the throttle, vary

or snow ingestion into the the engine RPM from idle to full throttle. Repeat several

PVT system.

times as required. During this procedure, the throttle

should not be held at the full position for more than 10

seconds. Clutch seals should be inspected for damage if

repeated leaking occurs.

Clutch malfunction.

Contact your Polaris dealer for inspection of clutch com-

ponents.

Poor engine performance. Check for fouled plugs or foreign material in gas tank,

fuel lines, or carburetor. Contact your dealer for service.

118

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TROUBLESHOOTING

Engine Doesn’t Turn Over

Possible Cause

Solution

Tripped circuit breaker

Low battery voltage

Reset the breaker

Recharge 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

Turn fuel valve to reserve, refuel

Inspect and clean or replace

Drain the fuel system and refuel

Turn the fuel valve on

Clogged fuel valve or filter

Water is present in fuel

Fuel valve is turned off

Old or non-recommended fuel

Fouled or defective spark plug(s)

No spark to spark plug

Crankcase filled with water or fuel

Overuse of choke

Replace with new fuel

Inspect plug(s), replace if necessary

Inspect plug(s), verify stop switch is on

Immediately see your Polaris dealer

Inspect, clean and/or replace spark plugs

Replace the filter

Clogged fuel filter

Low battery voltage

Recharge battery to 12.8 VDC

See your Polaris dealer

Mechanical failure

Engine Pings or Knocks

Possible Cause

Solution

Poor quality or low octane fuel

Incorrect ignition timing

Replace with recommended fuel

See your Polaris dealer

Set gap to specs or replace plugs

Incorrect spark plug gap or heat range

119

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TROUBLESHOOTING

Engine Backfires

Possible Cause

Solution

Weak spark from spark plugs

Incorrect spark plug gap or heat range

Old or non-recommended fuel

Incorrectly installed spark plug wires

Incorrect ignition timing

Inspect, clean and/or replace spark plugs

Set gap to specs or replace plugs

Replace with new fuel

See your Polaris dealer

Mechanical failure

Engine Runs Irregularly, Stalls or Misfires

Possible Weak Spark Cause

Fouled or defective spark plugs

Worn or defective spark plug wires

Incorrect spark plug gap or heat range

Loose ignition connections

Water present in fuel

Solution

Inspect, clean and/or replace spark plugs

See your Polaris dealer

Set gap to specs or replace plugs

Check all connections and tighten

Replace with new fuel

Low battery voltage

Recharge battery to 12.8 VDC

Inspect and replace

Kinked or plugged fuel vent line

Incorrect fuel

Replace with recommended fuel

Inspect and clean or replace

See your Polaris dealer

Clogged air filter

Reverse speed limiter malfunction

Electronic throttle control malfunction

Other mechanical failure

See your Polaris dealer

Possible Lean Fuel Mixture Cause Solution

Low or contaminated fuel

Low octane fuel

Add or change fuel, clean the fuel system

Replace with recommended fuel

Replace filter

Clogged fuel filter

Incorrect jetting

See your Polaris dealer

Possible Rich Fuel Mixture Cause Solution

Overuse of choke

Fuel is very high octane

Incorrect jetting

Inspect, clean and/or replace spark plugs

Replace with lower octane fuel

See your Polaris dealer

120

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TROUBLESHOOTING

Engine Stops or Loses Power

Possible Cause

Solution

Out of fuel

Turn fuel valve to reserve, refuel

Inspect and replace

Kinked or plugged fuel vent line

Water present in fuel

Replace with new fuel

Overuse of choke

Inspect, clean and/or replace spark plugs

See your Polaris dealer

Fouled or defective spark plugs

Worn or defective spark plug wires

Incorrect spark plug gap or heat range

Loose ignition connections

Low battery voltage

Set gap to specs or replace plugs

Check all connections and tighten

Recharge battery to 12.8 VDC

Replace with recommended fuel

Inspect and clean or replace

See your Polaris dealer

Incorrect fuel

Clogged air filter

Reverse speed limiter malfunction

Electronic throttle control malfunction

Other mechanical failure

Overheated engine

See your Polaris dealer

Clean radiator screen and core if equipped

Clean engine exterior

See your Polaris dealer

121

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WARRANTY

LIMITED WARRANTY

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

WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects

in material or workmanship. Polaris also gives a one year limited warranty on the final drive

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

or replacement of defective parts which are covered by this warranty. This warranty begins

on the date of purchase. This warranty is transferrable to another consumer during the war-

ranty period through a Polaris dealer.

REGISTRATION

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

submitted to Polaris within ten days. Upon receipt of this registration, Polaris will record

the registration for warranty. THE PURCHASERMUST COMPLETEAN ATVSAFETY

TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID

WARRANTY ON THE ATV. No verification of registration will be sent to the purchaser

as the copy of the Warranty Registration Form will be the warranty entitlement. If you have

not signed the original registration and received the “customer copy”, please contact your

dealer immediately. NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS

YOUR ATV IS REGISTERED WITH POLARIS.

Initial dealer preparation and set-up of your ATV is very important in ensuring trouble-free

operation. Purchasing a machine in the crate or without proper dealer set-up will void your

warranty coverage.

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 al-

tered structurally, modified, neglected, improperly maintained, used for racing, or used for

purposes other than for which it was manufactured, or for any damages which occur during

trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addi-

tion, this warranty does not cover physical damage to paint or finish, stress cracks, tearing

or puncturing of upholstery material, corrosion, or defects in parts, components or the ATV

due to fire, explosions or any other cause beyond Polaris’ control.

This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are

not compatible with the ATV. The exclusive remedy for breach of this warranty shall be, at

Polaris’ exclusive option, repair or replacement of any defective materials, or components

or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY

REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.

POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL,

CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER

ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CON-

TRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. Some states do not per-

mit theexclusion orlimitation ofincidental orconsequential damagesor implied warranties,

so the above limitations or exclusions may not apply to you if inconsistent with controlling

state law.

122

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WARRANTY

WARRANTY COVERAGE AND EXCLUSIONS:

LIMITATIONS OF WARRANTIES AND REMEDIES

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED

WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR

PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRAN-

TY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT

STATED IN THIS WARRANTY. Some states do not allow limitations on how long an im-

plied warranty lasts, so the above limitation may not apply to you if inconsistent with con-

trolling state law.

HOW TO OBTAIN WARRANTY SERVICE

If your ATV requires warranty service, you must take it to a Polaris dealer authorized to re-

pair 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 war-

ranty service.

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

additional assistance they will contact the appropriate personnel at Polaris.

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

from state to state.

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

will remain in effect.

Engine Oil

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

mend the use of Polaris engine oil.

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

warranty.

123

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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.

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: 1-763-417-8650

Canada: 1-204-925-7100

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INDEX

Accessories . . . . . . . . . . . . . . . . . . . 69

Engine Storage . . . . . . . . . . . . . . . 112

Equipment Modifications . . . . . . . . 11

Exhaust Emission Control System . 68

Adjustments . . . . . . . . . . . . . . . . 85-95

Age Restrictions . . . . . . . . . . . . . . . .

Air Filter . . . . . . . . . . . . . . . . . . . . 100

All Wheel Drive . . . . . . . . . . . . . 47-48

Auxiliary Brake . . . . . . . . . . . . 43, 87

AWD . . . . . . . . . . . . . . . . . . . . . . 47-48

FEATURES . . . . . . . . . . . . . . . . 37-48

Filter Systems . . . . . . . . . . . . . . . . 100

Front Gearcase Oil Change . . . . . . . 83

Front Gearcase Oil Check . . . . . . . . 83

Front Wheel Hub Tightening . . . . . 93

Fuel Filter . . . . . . . . . . . . . . . . . . . . 44

Fuel Safety . . . . . . . . . . . . . . . . . . . 32

Fuel Stabilizer . . . . . . . . . . . . . . . . 111

Fuel Tank . . . . . . . . . . . . . . . . . . . . 44

Fuel Valve . . . . . . . . . . . . . . . . . . . . 44

Battery . . . . . . . . . . . . . . . . . . 107-109

Battery Charging . . . . . . . . . . . 108-109

Battery Installation . . . . . . . . . . . . 107

Battery Removal . . . . . . . . . . . . . . 107

Battery Storage . . . . . . . . . . . . . . . 108

Brake Lever . . . . . . . . . . . . . . . . . . 40

Brakes . . . . . . . . . . . . . . . . . . 41, 86-87

Break-In Period . . . . . . . . . . . . . . . . 49

Breather Filter/Hose . . . . . . . . . . . 100

Gear Selector . . . . . . . . . . . . . . . . . . 45

Camber and Caster . . . . . . . . . . . . . 88

Carburetor . . . . . . . . . . . . . . . . . . . . 90

Choke . . . . . . . . . . . . . . . . . . . . . . . 44

Cleaning and Storage . . . . . . . 110-112

Cleaning the ATV . . . . . . . . . . . . . 110

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

CONTROLS . . . . . . . . . . . . . . . . 37-48

Coolant Level . . . . . . . . . . . . . . . 96-97

Cooling System . . . . . . . . . . . . . 96-97

Crankcase Emission Control System 68

Handlebars . . . . . . . . . . . . . . . . . . . 89

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

Headlight Lamp Replacement . . . . . 98

Helmet . . . . . . . . . . . . . . . . . . . . . . 36

High Beam Adjustment . . . . . . . . . . 98

Indicator Lamp Replacement . . . . . 99

Indicator Lights . . . . . . . . . . . . . . . . 38

K-Turn . . . . . . . . . . . . . . . . . . . . . . 63

Disengaging Wheel Hubs . . . . . . . . 48

Drive Chain . . . . . . . . . . . . . . . . . . 84

Driving Downhill . . . . . . . . . . . . . . 62

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

Driving on Slippery Surfaces . . . . . 58

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

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

Driving Safely . . . . . . . . . . . . . . . 56-67

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

Driving Uphill . . . . . . . . . . . . . . 60-61

Light Switches . . . . . . . . . . . . . . . . 38

Lights . . . . . . . . . . . . . . . . . . . . . 98-99

Lubrication Recommendations . . 74-84

LUBRICATION . . . . . . . . . . . . 69-113

Main Switch . . . . . . . . . . . . . . . . . . 37

MAINTENANCE . . . . . . . . . . . 69-113

Maintenance Record . . . . . . . . . . 76-77

Maintenance Schedule . . . . . . . . 69-73

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

Electrical Switches . . . . . . . . . . . . . 37

EMISSION CONTROL SYSTEMS 68

Engaging Wheel Hubs . . . . . . . . . . 47

Engine Cooling System . . . . . . . 96-97

Engine Oil Check . . . . . . . . . . . . . . 79

Noise Emission Control System . . . 68

125

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INDEX

Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Oil Change . . . . . . . . . . . . . . . . . 80-81

Oil Filter Change . . . . . . . . . . . . 80-81

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

Operator Safety . . . . . . . . . . . . . . . 7-31

Override Switch . . . . . . . . . . . . . . . 37

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

Starting the Engine . . . . . . . . . . . 51-53

Steering Assembly . . . . . . . . . . . . . 88

Stop Switch . . . . . . . . . . . . . . . . . . . 37

Storage Tips . . . . . . . . . . . . . . 111-112

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

Taillight/Brakelight

Parking Brake . . . . . . . . . . . . . . . . . 42

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

Periodic Maintenance Schedule . 69-73

POLARIS PRODUCTS . . . . . . . . 117

Pre-Ride Inspection . . . . . . . . . . . . . 50

Premium 4 Synthetic Oil . . . . . . . . . 78

PVT Drying . . . . . . . . . . . . . . . . . 105

PVT System . . . . . . . . . . . . . . 104-105

Lamp Replacement . . . . . . . . . 99

Throttle Cable Freeplay . . . . . . . . . . 88

Throttle Lever . . . . . . . . . . . . . . . . . 39

Tire Tread Depth . . . . . . . . . . . . . . . 93

Toe Alignment . . . . . . . . . . . . . . . . 85

Towing Capacities . . . . . . . . . . . . . . 54

Transmission Gear Selector . . . . . . . 45

Transmission Oil Change . . . . . . . . 82

Transmission Oil Check . . . . . . . . . 82

Transporting the ATV . . . . . . . . . . 113

TROUBLESHOOTING . . . . . 118-121

Turning Around on a Hill . . . . . . . . 63

Radiator Coolant Level . . . . . . . . . 97

Rear Drive Chain Slack . . . . . . . . 94-95

Rear Spring . . . . . . . . . . . . . . . . . . . 88

Recoil Housing . . . . . . . . . . . . . . . 103

Recoil Starter . . . . . . . . . . . . . . . . . 46

VEHICLE IDENTIFICATION

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

Vehicle Immersion . . . . . . . . . . . . 102

Safe Riding Gear . . . . . . . . . . . . . . . 36

SAFETY . . . . . . . . . . . . . . . . . . . . 7-36

Safety Decals and Locations . . . . 33-35

WARRANTY . . . . . . . . . . . . . 122-124

Washing the ATV . . . . . . . . . . . . . 110

Waxing the ATV . . . . . . . . . . . . . . 110

Safety Training . . . . . . . . . . . . . . . . .

Sidehilling . . . . . . . . . . . . . . . . . . . 59

Spark Arrestor . . . . . . . . . . . . . 68, 106

Spark Plug Removal/Replacement 101

Spark Plugs . . . . . . . . . . . . . . . . . . 101

SPECIFICATIONS . . . . . . . . . 114-116

Starting a Cold Engine . . . . . . . . 51-52

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

Wheel Installation . . . . . . . . . . . . . . 92

Wheel Nut Torque Specifications . . 92

Wheel Removal . . . . . . . . . . . . . . . 91

126

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