Univex Offroad Vehicle Trail Blazer User Manual

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WARNING

The engine exhaust from this

product contains chemicals known

to cause cancer, birth defects or

other reproductive harm.

A card containing important ATV safety information should be attached

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

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

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

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

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

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

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

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

expressly prohibited.

Printed in U.S.A.

2005 Trail Blazer Owner’s Manual P/N 9919472

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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

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

recreational vehicles manufactured in the world today. Many years of

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

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

produced.

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

instructions and recommendations in this owner’s manual. Your

manual contains instructions for minor maintenance, but information

about major repairs is outlined in the Polaris Service Manual and

should be performed only by a Factory Certified Master Service Dealer

(MSD) Technician.

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

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

service needs during, and after, the warranty period.

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

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

Have your accessories and clothing delivered right to your door!

POLARIS and POLARIS THE WAY OUT are registered trademarks of

Polaris Industries Inc.

LOCTITE is a registered trademark of LOCTITE Corporation.

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TABLE OF CONTENTS

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

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

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

FEATURES AND CONTROLS . . . . . . . . . . . . . . . 32

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

EMISSION CONTROL SYSTEMS . . . . . . . . . . . . 63

MAINTENANCE AND LUBRICATION . . . . . . . . . 64

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 103

POLARIS PRODUCTS . . . . . . . . . . . . . . . . . . . . . 106

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . 107

WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

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VEHICLE IDENTIFICATION NUMBERS

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

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

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

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

must be replaced.

31XX

Vehicle Model Number:

Frame VIN (1):

Engine Serial Number:

(right front side of engine crankcase)

Key Number (2):

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SAFETY

Operator Safety

WARNING

Failure to follow the warnings contained in this manual can result

in serious injury or death.

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

vehicle handles differently than other vehicles, such as

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

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

over obstacles, if you fail to take proper precautions.

Read and understand your owner’s manual and all warnings

before operating a Polaris ATV.

Age Restrictions

This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited

for anyone under 16 years of age.

Know Your Vehicle

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

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

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

information about all aspects of your vehicle, including safe operating

procedures.

Safety Training

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

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

also provided with printed materials that explain safe operating

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

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

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

Polaris dealer.

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

and regulations concerning the operation of 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 vehicle or in this manual, alerts

you to the potential for personal injury.

WARNING

The safety alert warning indicates a potential hazard that may

result in serious injury or death.

CAUTION

The safety alert caution indicates a potential hazard that may

result in minor personal injury or damage to the vehicle.

CAUTION

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

vehicle.

NOTE:

A note will alert you to important information or instructions.

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SAFETY

Operator Safety

WARNING

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

instructions and procedures, which are outlined in further detail

within your owner’s manual.

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

procedures described.

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

course. Beginners should receive training from a certified instructor.

Contact an authorized Polaris ATV dealer or call Polaris at

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

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

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

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

ty training course.

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

walks, driveways, parking lots, and streets.

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

a dirt or gravel road.

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

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

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

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

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

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

S Never attempt wheelies, jumps or other stunts.

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

operating condition. Always follow the inspection and maintenance

procedures and schedules outlined in your owner’s manual.

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

rests of the ATV during operation.

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

miliar terrain. Be alert to changing terrain conditions.

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

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

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

speeds. Do not turn at excessive speeds.

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SAFETY

Operator Safety

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

it’s been involved in an accident.

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

Practice on smaller hills before attempting larger hills.

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

rain carefully before 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.

WARNING

POTENTIAL HAZARD

Operating an ATV

on paved

surfaces, including

sidewalks, paths,

parking lots, and

driveways.

WHAT CAN HAPPEN

ATV tires are designed for

off-road use. Operating on

paved surfaces may

seriously affect the handling and

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

and/or injury.

HOW TO AVOID THE HAZARD

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

slowly and avoid sudden turns or stops.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating this ATV on

public streets, roads or

highways.

WHAT CAN HAPPEN

The ATV could collide

with another vehicle.

HOW TO AVOID THE HAZARD

Never operate the ATV on any

public street, road or highway,

including dirt and gravel roads. In many states

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

WARNING

POTENTIAL HAZARD

Operating this ATV without

wearing an approved

helmet, eye protection and

protective clothing.

WHAT CAN HAPPEN

Operating an ATV without

an approved helmet

increases the risk of a

severe head injury or

death in the event of an

accident.

Operating without eye protection could result in an accident and

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

accident.

HOW TO AVOID THE HAZARD

Always wear an approved helmet that fits properly.

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

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

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating the ATV after consuming

alcohol or drugs.

WHAT CAN HAPPEN

Consumption of alcohol and/or drugs

could seriously affect operator

judgment. Reaction time may be slower

and operator balance and perception

could be affected.

Consuming alcohol and/or drugs before

or while operating an ATV could result in

an accident causing severe injury or death.

HOW TO AVOID THE HAZARD

Never consume alcohol or drugs before or while operating an

ATV.

WARNING

POTENTIAL HAZARD

Operating the ATV at excessive speeds.

WHAT CAN HAPPEN

Excessive speed increases the operator’s chance of losing

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

HOW TO AVOID THE HAZARD

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

visibility and operating conditions, and your experience.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Attempting wheelies, jumps

and other stunts.

WHAT CAN HAPPEN

Attempting stunts increases

the chance of an accident,

including an overturn.

HOW TO AVOID THE

HAZARD

Never attempt wheelies,

jumps, or other stunts. Avoid

exhibition driving.

WARNING

POTENTIAL HAZARD

Failure to inspect the ATV before operating.

Failure to properly maintain the ATV.

WHAT CAN HAPPEN

Poor maintenance increases the possibility of an accident or

equipment damage.

HOW TO AVOID THE HAZARD

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

safe operating condition.

Always follow the inspection and maintenance procedures and

schedules described in the owner’s manual.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Removing hands from the handlebars or feet from the footrests

during operation.

WHAT CAN HAPPEN

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

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

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

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

injury.

HOW TO AVOID THE HAZARD

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

footrests of the ATV during operation.

WARNING

POTENTIAL HAZARD

Failure to use extra

caution when operating

the ATV on unfamiliar

terrain.

WHAT CAN HAPPEN

Unfamiliar terrain may

contain hidden rocks,

bumps, or holes that could

cause loss of control or

overturn.

HOW TO AVOID THE HAZARD

Travel slowly and use extra caution when operating on unfamiliar

terrain. Always be alert to changing terrain conditions.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Failure to use extra

caution when operating on

excessively rough,

slippery or loose terrain.

WHAT CAN HAPPEN

Operating on excessively

rough, slippery or loose

terrain could cause loss of

traction or loss of control,

which could result in an

accident or overturn.

HOW TO AVOID THE HAZARD

Do not operate on excessively rough, slippery or loose terrain

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

the ATV on such terrain.

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

WARNING

POTENTIAL HAZARD

Turning improperly.

WHAT CAN HAPPEN

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

or overturn.

HOW TO AVOID THE HAZARD

Always follow proper procedures for turning as described in the

owner’s manual.

Practice turning at slow speeds before attempting to turn at faster

speeds.

Never turn at excessive speed.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating on excessively steep hills.

WHAT CAN HAPPEN

The vehicle may overturn.

HOW TO AVOID THE HAZARD

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

Never operate the ATV on hills steeper than 25_.

Practice on smaller hills before attempting large hills.

WARNING

POTENTIAL HAZARD

Climbing hills improperly.

WHAT CAN HAPPEN

Improper hill climbing could

cause loss of control or

overturn.

HOW TO AVOID THE

HAZARD

Always follow proper

procedures for climbing

hills as described in the

owner’s manual.

Always check the terrain

carefully before ascending

any hill.

Never operate the ATV on hills steeper than 25_.

Never climb hills with excessively slippery or loose surfaces.

Shift your weight forward.

Never open the throttle suddenly while traveling uphill. The ATV

could flip over backwards.

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

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

side of the hill.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Traveling downhill

improperly.

WHAT CAN HAPPEN

Improperly descending a hill

could cause loss of control

or overturn.

HOW TO AVOID THE

HAZARD

Always follow proper

procedures for traveling

down hills as described in

the owner’s manual.

NOTE: A special technique

is required when braking

while traveling downhill. See

page 54.

Always check the terrain carefully before descending a hill.

Shift your weight backward.

Never travel down a hill at high speed.

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

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

when possible.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Improperly crossing hills and

turning on hills.

WHAT CAN HAPPEN

Improperly crossing or

turning as hills could cause

loss of control or overturn.

HOW TO AVOID THE

HAZARD

Never attempt to turn the

ATV around on any hill until

you’ve mastered the turning

technique (on level ground)

as described in the owner’s

manual. See page 55. 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 55.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Improperly operating over obstacles.

WHAT CAN HAPPEN

Operating over obstacles could cause loss of control or overturn.

HOW TO AVOID THE HAZARD

Before operating in a new area, check for obstacles.

Avoid operating over large obstacles such as rocks and fallen

trees when possible. If unavoidable, use extreme caution and

always follow proper procedures as outlined in the owner’s

manual.

WARNING

POTENTIAL HAZARD

Skidding or sliding.

WHAT CAN HAPPEN

Skidding or sliding can cause loss of control.

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

HOW TO AVOID THE HAZARD

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

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

WARNING

POTENTIAL HAZARD

Improperly operating in reverse.

WHAT CAN HAPPEN

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

severe injury.

HOW TO AVOID THE HAZARD

Before shifting into reverse gear, always check for obstacles or

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

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating the ATV through deep or fast-flowing water.

WHAT CAN HAPPEN

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

could lead to an accident or overturn.

HOW TO AVOID THE HAZARD

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

unavoidable to enter water that exceeds the recommended

maximum depth (see page 56), travel slowly, balance your weight

carefully, avoid sudden movements, and maintain a slow and

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

do not make sudden throttle changes.

Wet brakes may have reduced stopping ability. Always test the

brakes after leaving water. If necessary, apply them several

times to let friction dry out the pads.

WARNING

POTENTIAL HAZARD

Operating this ATV with improper tires, or with improper or

uneven tire pressure.

WHAT CAN HAPPEN

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

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

HOW TO AVOID THE HAZARD

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

Always maintain proper tire pressure as specified.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating the ATV with improper modifications.

WHAT CAN HAPPEN

Improper installation of accessories or modification of the ATV

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

HOW TO AVOID THE HAZARD

Never modify the ATV through improper installation or use of

accessories. All parts and accessories added to the vehicle must

be genuine Polaris Industries Inc. or equivalent components

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

according to approved instructions. See your authorized Polaris

ATV dealer for more information.

WARNING

POTENTIAL HAZARD

Overloading the ATV or carrying/towing cargo improperly.

WHAT CAN HAPPEN

Overloading and towing can cause changes in vehicle handling,

which could lead to loss of control or an accident.

HOW TO AVOID THE HAZARD

Never exceed the stated load capacity for this ATV.

Cargo should be properly distributed and securely attached.

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

greater distance for braking.

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

cargo or pulling a trailer. See page 60.

WARNING

POTENTIAL HAZARD

Operating on frozen bodies of water.

WHAT CAN HAPPEN

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

fall through the ice.

HOW TO AVOID THE HAZARD

Never operate the ATV on a frozen body of water.

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SAFETY

Operator Safety

WARNING

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

the vehicle resulting in serious injury or death. Always remove

the ignition key when the vehicle is not in use.

WARNING

After any overturn or accident, have a qualified service dealer

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

limited to) brakes, throttle and steering systems.

WARNING

Safe operation of this rider-active vehicle requires good

judgement and physical skills. Persons with cognitive or physical

disabilities who operate this vehicle have an increased risk of

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

death.

CAUTION

Always keep combustible materials away from the exhaust

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

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SAFETY

Safety Decals and Locations

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

and follow the instructions of the decals and other warnings on the

ATV carefully. If any of the decals shown 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.

7172665

WARNING

7172566

WARNING

Moving parts hazard under belt-clutch guard. To

prevent serious injury, do not operate vehicle

with guard removed.

7172664

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

7172563

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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:

7172560

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SAFETY

Safety Decals and Locations

WARNING

Operating this ATV if you are under

the age of 16 increases your chance

of severe injury or death.

NEVER operate this ATV if you are

under age 16.

7172559

Under Seat

RH Swingarm

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:

OVERRIDE

SWITCH

THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT

INTENDED FOR USE ON PUBLIC ROADS.

Reverse Speed is

limited.

CE VÉHICULE EST UN VÉHICULE TOUT TERRAIN QUI NiEST

PAS DESTINÉ À ÊTRE UTILISÉ SUR LES CHEMINS PUBLICS.

Reverse override is

controlled by the

override switch.

See your Owner’s

Manual.

7079906

7171492

Canadian Certification Decal

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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

This vehicle is equipped with a reverse speed

limiter system. To gain additional power while

backing, depress the override switch.

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: Turning off the main switch will shut off 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

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

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.

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. Oil Warning (indicates a low oil level.

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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.

1. Position the ATV on level ground

with the handlebars straight.

2. View the fluid level through the

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: 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. We recommend the use of Polaris

DOT 3 brake fluid. Do not overfill.

3. If the fluid level is low, add DOT 3 brake fluid only. See page 106

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

Brake Lever

The front and rear brakes are applied by

squeezing the brake lever (1) toward the

handlebar. The front and rear brakes are

hydraulically activated disc type brakes

that are activated by only one lever.

Always test brake lever travel and master

cylinder fluid level before riding. When

squeezed, the lever should feel firm. Any sponginess would indicate a

possible fluid leak or low master cylinder fluid level, which must be

corrected before riding. Contact your dealer for proper diagnosis and

repairs.

WARNING

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

braking, which could cause an accident. Never operate the ATV

with a spongy-feeling brake lever.

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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 (1) two or three times, then

squeeze and hold.

2. Push the park brake lock (2)

forward to engage the brake.

Release the brake lever.

3. To release the parking brake lock,

squeeze and release the brake

lever. It will return to its unlocked

position.

Important Safeguards

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

ways block the wheels to prevent rolling.

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

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

position.

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

hill. Always block the wheels to prevent rolling.

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FEATURES AND CONTROLS

Auxiliary Brake

WARNING

Aggressively applying the 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 brake (1), is

located on the inside of the right

floor board and is operated by

the right foot. The auxiliary

brake serves as a backup to the

main brake system if the main

system becomes inoperative.

If the rear wheels slide while

using the auxiliary brake, reduce

brake pedal pressure to brake the

rear wheels without skidding.

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

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

the fluid level between the maximum and minimum marks.

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FEATURES AND CONTROLS

Choke

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

procedure on page 47 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 valve to ON position

after refueling.

Fuel Tank

The fuel tank filler cap (2) is located

directly below the handlebar. Use

either leaded or unleaded gasoline with

a minimum pump octane number of

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

specifications section beginning on

page 103 for capacities.

Fuel Filter

Replace the in-line fuel filter at the intervals outlined in the Periodic

Maintenance Chart beginning on page 65. Do not attempt to clean the

fuel filter.

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FEATURES AND CONTROLS

Fuel Safety

WARNING

Gasoline is highly flammable and explosive under certain

conditions.

S Always exercise extreme caution whenever handling gasoline.

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

ventilated area.

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

area where refueling is performed or where gasoline is stored.

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

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

with soap and water and change clothing.

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

Engine exhaust fumes are poisonous and can cause loss of

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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FEATURES AND CONTROLS

Oil Injection Tank

CAUTION

Mixing brands or using a non-recommended oil may cause

serious engine damage. We recommend the use of Polaris

Premium Synthetic 2-cycle oil for your 2-cycle Polaris ATV.

Never substitute or mix oil brands.

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

refueling.

The oil injection tank filler cap (1)

is located on the front of the

vehicle. Refer to the specifications

section beginning on page 103

for capacities.

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FEATURES AND CONTROLS

Automatic Transmission Gear Selector

The transmission gear selector (1)

is located on the right side of the ATV.

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.

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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.

1. Position the vehicle on a level

surface and lock the parking

brake (see page 37).

2. Shift the transmission into

neutral.

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

switch is in the ON position.

NOTE: If the engine is cold, use the choke as outlined on page 47.

4. Reach under the side panel and grasp the 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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OPERATION

Break-In Period

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

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

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

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

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

CAUTION

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

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

throttle or high speeds for extended periods during the first three

hours of use.

Use of any oils other than those recommended by Polaris may

cause serious engine damage. We recommend the use of

Polaris 2-cycle oil for your 2-cycle engine.

Lack of proper lubrication will cause serious engine damage.

Always fill the oil tank when refueling the ATV.

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OPERATION

Break-In Period

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

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

provide the necessary engine lubrication without pre-mixing.

1. Premix the recommended oil with gasoline in a suitable gas

container. Refer to the chart below for ratios.

2. Fill the fuel tank (see page 39), then fill the oil tank with the

recommended oil.

3. Drive slowly at first. Vary the throttle positions.

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

on the daily pre-ride inspection checklist on page 46.

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

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

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

oil pump bleeding and repeat the pre-mix procedure.

Fuel/Oil Premix Chart

Fuel

Gallons (Liters)

1 (3.8)

Oil @ 40:1

Ounces (Liters)

3.2 (.09)

5 (18.9)

16 (.47)

10 (37.9)

32 (.95)

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OPERATION

Pre-Ride Inspection

WARNING

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

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

to ensure it’s in proper operating condition.

Pre-Ride Checklist

Item

Remarks

See

Page

Brake system / lever travel

Brake fluid

Ensure proper operation

Ensure proper level

36, 75

Auxiliary brake

Front suspension

Rear suspension

Steering

Ensure proper operation

Inspect, lubricate if necessary

Ensure free operation

Tires

Inspect condition and pressure

Inspect, ensure fastener tightness

Wheels / fasteners

Frame nuts, bolts, fasteners Inspect, ensure tightness

Fuel and oil

Ensure proper levels

Ensure proper level

Coolant level (if applicable)

Coolant hoses (if applicable) Inspect for leaks

Throttle

Ensure proper operation

33, 78

Indicator lights / switches

Engine stop switch

Drive chain

Ensure operation

Ensure proper operation

Check condition / slack, lubricate as

needed

Air filter, pre-filter

Air box sediment tube

Headlamp

Inspect, clean

Drain deposits whenever visible

Check operation

Brake light / tail lamp

Check operation, apply Polaris dielec-

tric grease when lamp is replaced

Riding gear

Wear helmet, goggles, protective

clothing

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OPERATION

Starting the Engine

Starting a Cold Engine

WARNING

Engine exhaust contains poisonous carbon monoxide and can

cause loss of consciousness resulting in severe injury or death.

Never run an engine in an enclosed area.

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 valve is on.

2. Sit on the vehicle and pull the choke

knob (1) out until it stops.

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.

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 for

a maximum of five seconds. Release the key when the engine

starts. If it doesn’t start, release the key and wait five seconds.

Activate the starter for another five seconds. Repeat 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 and place 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 (pulled half way out) may be

necessary.

NOTE: If the engine is over-choked when warm, depress the throttle

lever fully while cranking to aid in starting.

4. 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.

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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 that drives both

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

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

when turning and the inside tire must slip traction slightly.

To 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.

WARNING

Failure to exercise care when operating on slippery surfaces can

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

and serious injury or death.

Never apply the brakes during a skid.

Do not operate on excessively slippery surfaces.

Always reduce speed and use additional caution.

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OPERATION

Driving Safely

Driving Uphill

Whenever traveling uphill, follow

these precautions:

1. Always travel straight uphill.

2. Avoid steep hills (25_

maximum).

3. Keep both feet on the

footrests.

4. Transfer your weight forward.

5. Proceed at a steady rate of

speed and throttle opening.

6. Remain alert and be

25_ Maximum

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 55.

WARNING

Braking and handling are greatly affected when operating in hilly

terrain. Improper procedure could cause loss of control or

overturn and result in serious injury or death.

Avoid climbing steep hills (25_ maximum).

Use extreme caution when operating on hills, and follow proper

operating procedures outlined in the owner’s manual.

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OPERATION

Driving Safely

Sidehilling

WARNING

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

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

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

procedures as outlined in the owner’s manual.

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

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

necessary, follow these precautions:

1. Slow down.

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

while keeping your feet on the footrests.

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

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

downhill, if possible, or dismount on the uphill side

immediately!

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OPERATION

Driving Safely

Driving Downhill

Whenever descending a hill, follow these precautions:

1. Proceed directly downhill.

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

3. Slow down.

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

lever.

NOTE: Familiarize yourself with operation of the auxiliary rear brake

pedal for additional braking in the event of normal service

brake loss.

WARNING

Excessive speed can cause loss of control and lead to serious

injury or death. Always operate slowly when traveling downhill.

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OPERATION

Driving Safely

Turning Around on a Hill

WARNING

Improper hill climbing procedures could cause loss of control or

overturn and result in serious injury or death.

Avoid climbing steep hills (25_ maximum).

Use extreme caution when operating on hills, and follow proper

operating procedures outlined in the owner’s manual.

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

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

while climbing a hill is the K-turn:

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

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

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

vehicle is pointing straight uphill.

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

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

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

pointing across the hill or slightly downward.

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

side, keeping body weight uphill.

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

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

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

8’

Uphill

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OPERATION

Driving Safely

Driving Through Water

Your ATV can operate through water with a maximum recommended

depth equal to the bottom of the footrests (1). Follow these procedures

when operating through water:

1. Determine water depths and current before crossing.

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

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

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

lever until braking action is normal.

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

outlined in the maintenance chart. See page 64. The following areas

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

gearcases and all grease fittings.

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OPERATION

Driving Safely

Driving Through Water

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 91. 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

Hauling Cargo

2/3

1/3

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

(if equipped with racks). Always read and understand the load

distribution warning labels on the vehicle, and never exceed the weight

capacities outlined in the specifications section of the owner’s manual

and on the safety decals.

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

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

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

stable driving conditions. Do not obstruct the headlight beam with

cargo.

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OPERATION

Hauling Cargo

WARNING

Hauling cargo improperly can alter vehicle handling and may

cause loss of control or brake instability and result in serious

injury or death. Always follow these precautions when hauling

cargo:

S REDUCE SPEED AND ALLOW GREATER DISTANCE FOR

BRAKING WHEN HAULING CARGO.

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

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

hilly terrain, reduce speed and cargo to maintain stable driving

conditions. Carrying loads on one rack only increases the pos-

sibility of vehicle overturn.

S LOADS MUST BE CARRIED AS LOW ON THE RACKS AS

POSSIBLE. Carrying loads high on the racks raises the center

of gravity of the vehicle and creates a less stable operating

condition. When cargo loads are carried high on the racks, the

weight of the loads must be reduced to maintain stable operat-

ing conditions.

S ALL LOADS MUST BE SECURED BEFORE OPERATING.

Unsecured loads can create unstable operating conditions,

which could result in loss of control of the vehicle.

S OPERATE ONLY WITH STABLE AND SAFELY ARRANGED

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

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

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

vehicle.

S HEAVY LOADS CAN CAUSE BRAKING AND CONTROL

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 maneuver-

ability may be adversely affected, causing the machine to over-

turn.

S DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carry-

ing loads on the front rack.

S DO NOT TRAVEL FASTER THAN THE RECOMMENDED

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

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

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

while cornering, or while ascending or descending a hill.

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OPERATION

Driving Safely

Parking on an Incline

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

these precautions:

1. Turn the engine off.

2. Place the transmission in gear.

3. Set the parking brake.

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

illustration.

5. Shut off the fuel supply.

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EMISSION CONTROL SYSTEMS

Noise Emission Control System

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

may affect compliance with state and local noise level requirements.

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.

Electromagnetic Interference

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

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MAINTENANCE AND LUBRICATION

Accessories

Auxiliary power outlets provide 12V power for operating accessories

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

Periodic Maintenance Chart

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

most reliable condition. Inspection, adjustment and lubrication of

important components are explained in the periodic maintenance chart.

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

inspection reveals the need for replacement parts, use genuine Polaris

parts available from your Polaris dealer.

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

with safe service and adjustment procedures, have a

qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average

riding conditions and an average vehicle speed of approximately 10

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

serviced more frequently.

Severe Use Definition

S Frequent immersion in mud, water or sand

S Racing or race-style high RPM use

S Prolonged low speed, heavy load operation

S Extended idle

S Short trip cold weather operation

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

weather can indicate contaminants collecting in the oil sump or

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

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

determine the cause or see your dealer.

Maintenance Chart Key

Perform these procedures more frequently for vehicles subjected to

severe use.

Emission Control System Service (California)

Have an authorized Polaris dealer perform these services.

WARNING

Improperly performing the procedures marked with a J could

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

Have an authorized Polaris dealer perform these services.

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

Item

Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar

Miles

(Km)

Steering

Pre-Ride

Make adjustments as need-

ed. See Pre-Ride Checklist

on page 46.

Front suspension

Rear suspension

Tires

Brake fluid level

Brake lever travel

Brake system

Wheels/fasteners

Frame fasteners

Engine oil level

Air filter, pre-filter

Daily

Inspect; clean often

Drain deposits when visible

Check operation

Air box sediment

tube

Headlamp

Tail light

Daily

Check operation; apply

dielectric grease if replacing

Air filter,

Weekly

Inspect; replace as needed

main element

Recoil housing

Drain water as needed,

check often if operating in

wet conditions

Brake pad wear

10 H

Monthly

100 (160)

Inspect periodically

Battery

20 H

25 H

Monthly

200 (320)

250 (400)

Check terminals; clean; test

Inspect level; change yearly

Inspect; clean if needed

Transmission oil

Engine breather

filter (if equipped)

General

lubrication

50 H

3 M

500 (800)

Lubricate all fittings, pivots,

cables, etc.

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Item

Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar

Miles

(Km)

Carburetor float

bowl

50 H

6 M

500 (800)

Drain bowl periodically and

prior to storage

Throttle Cable/

ETC Switch

Inspect; adjust; lubricate;

replace if necessary

Choke cable

Inspect; adjust; lubricate;

replace if necessary

Carburetor air

intake ducts/

flange

Inspect ducts for proper

sealing/air leaks

Drive belt

50 H

6 M

500 (800)

Inspect; adjust; replace as

needed

Engine oil change 100 H

1000 (1600) Perform a break-in oil

change at one month

Oil filter change

Valve clearance

Fuel system

100 H

6 M

1000 (1600) Replace with oil change

12 M

1000 (1600) Inspect; adjust

1000 (1600) Check for leaks at tank cap,

lines, fuel valve, filter, pump,

carburetor; replace lines

every two years

Fuel filter

100 H

12 M

1000 (1600) Replace yearly

Engine mounts

100 H

12 M

1000 (1600) Inspect

Exhaust muffler/

pipe

Spark plug

Ignition Timing

Wiring

100 H

12 M

1000 (1600) Inspect; replace as needed

1000 (1600) Inspect

1000 (1600) Inspect for wear, routing,

security; apply dielectric

grease to connectors

subjected to water, mud, etc.

Clutches (drive

and driven)

100 H

12 M

1000 (1600) Inspect; clean; replace worn

parts

Front wheel

bearings

1000 (1600) Inspect; replace as needed

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Item

Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar

Miles

(Km)

Brake fluid

200 H

300 H

24 M

36 M

2000 (3200) Change every two years

3000 (4800) Clean out

Spark arrestor

Idle speed

Adjust as needed

Toe adjustment

Inspect periodically; adjust

when parts are replaced

Headlight aim

Adjust as needed

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

Emission Control System Service (California)

Have an authorized Polaris dealer perform these services.

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Record

Use the following chart to record periodic maintenance.

Maintenance

Interval

Performed

Servicing Servicing

Remarks

Date

Dealer

or Person

10 hrs.

20 hrs.

50 hrs.

100 hrs.

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Check and lubricate all components at the intervals outlined in the

Periodic Maintenance Chart beginning on page 65.

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

Item

Lube

Method

Engine

Brakes

Polaris Injection Oil

DOT 3 fluid only

Fill oil tank. See page 41.

Maintain level between fill lines. See page

35.

Drive chain(s)

Transmission

(1) Ball Joint

O-ring chain lube or

SAE 80/90

Lubricate as often as required. Before

each ride in wet conditions

AGL Synthetic Gear-

case Lube

See Page 72.

Locate fitting on back side of struts and

grease with grease gun.

"L Grease

(2) Swing Arm

Bushings

Locate fittings on swing arm and grease

with grease gun.

(3) Axle Housing

Locate fittings on swing arm and grease

with grease gun.

(2)

(3)

(1)

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Polaris 2-Cycle Lubricants

Polaris Premium 2-cycle lubricants are the most advanced formulation

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

lubricants provide additives for 2-cycle engines that are lacking in

today’s fuel. These necessary additives keep ring grooves cleaner for

less ring sticking and improved overall engine cleanliness.

With new generation lubricity technology, Polaris oils excel in meeting

the lubrication demands of today’s high performance 2-cycle engines.

We recommend the use of these optimum oils for Polaris liquid cooled

or air cooled 2-cycle engines.

Polaris premium 2-cycle oils will mix with each other, but consistent

performance will be enhanced by selecting only one of the premium

oils and maintaining regular use of that oil through the life of the unit.

Your dealer will be able to assist you with that selection, based on your

operating conditions and riding style.

Never mix Polaris premium 2-cycle oils with any other brand of oil,

including Polaris Nature Oil Biodegradable oil. Their incompatibility

could result in engine damage. For best performance, we recommend

that you choose one oil for your ATV, then continue to use it for the

life of the unit.

See page 106 for the part numbers of Polaris products.

Polaris VES II Synthetic 2-Cycle Oil

Your vehicle has been primed with VES II synthetic oil. We

recommend the continued use of this oil for your ATV. This lubricant

has been specially formulated for low smoke, low odor, low deposits

and high lubricity.

Premium 2-Cycle Oil

Polaris also has a TC-W3 premium oil or Premium Gold Synthetic Oil

suitable for use in all of our 2-cycle products.

CAUTION

Mixing brands or using a non-recommended oil may cause

serious engine damage. We recommend the use of Polaris

2-cycle oils for your 2-cycle engine. Never mix oil brands.

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Engine Oil Check

The oil tank cap (1) is located forward

of the headlight. Check the oil before

each use of the vehicle. Refill the oil

when refueling.

1. Position the ATV on a level

surface.

2. Remove the oil tank cap and

inspect the oil level in the tank.

3. Add oil as needed to bring the

level to the full mark. Do not

overfill.

4. Reinstall the oil tank cap.

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MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Transmission Oil Check

The transmission oil dipstick (1) is located

on the right side of the vehicle. Check and

change the transmission oil at the intervals

outlined in the Periodic Maintenance Chart

beginning on page 65. Maintain the

transmission oil level in the SAFE

operating range (2). We recommend the

use of AGL Synthetic Gearcase Lubricant.

See page 106 for the part numbers of Polaris

products.

1. Position the ATV on a level surface.

2. Remove the transmission oil dipstick

and wipe it clean.

3. Reinstall the dipstick, then remove it and read the

oil level. If the level is low, add the recommended gearcase oil to

bring the level within the safe operating range on the dipstick.

4. Reinstall the dipstick.

Transmission Oil Change

1. Place a drain pan beneath the

transmission oil drain plug area.

2. Loosen the jam nut (A).

3. Turn the adjuster bolt (B) in to

allow the removal of the drain

plug (C).

4. Remove the drain plug and wipe

the magnetic end clean to remove

accumulated metallic filings.

5. After the oil has drained

completely, install a new sealing

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

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

turn an additional 1/2 turn.

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

8. Add the recommended lubricant through the dipstick hole until the

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

9. Check for leaks.

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MAINTENANCE AND LUBRICATION

Adjustments

Oil Pump Bleeding

CAUTION

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

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

oil, the oil pump must be bled. If the pump is not bled, air in the

lines may prevent oil delivery to the engine, resulting in severe

engine damage.

1. Fill the oil tank with the

recommended oil. See page 106 for

the part numbers of Polaris

products.

2. Loosen the bleeder screw one full

turn. Allow oil to flow from the

bleed screw for five to ten seconds,

then tighten the bleed screw.

CAUTION

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

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

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

3. Start the engine and rotate the oil pump lever (2) to its full open

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

seconds to purge all air from the system.

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MAINTENANCE AND LUBRICATION

Adjustments

Oil Pump

If it becomes necessary to increase oil flow into the fuel system, the oil

pump can be adjusted.

1. Before adjusting the oil pump, check the

engine idle RPM and carburetor settings

in the specifications section beginning

on page 103.

2. Loosen the throttle cable jam nut and

turn the adjuster (1) in or out until there

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

lever travel before the throttle slide starts

to open.

3. Place very slight pressure on the throttle

lever (2) until all freeplay is removed

from the throttle cable (to the point

where the carb slide is just starting to

rise).

4. Loosen the locknut (3).

Turn the adjuster in or out

until all freeplay is removed

from the oil pump cable (the

point where the oil pump

arm is just starting to move

off its stop). The pump stop

keeps the pump arm from

rotating any further down

than the idle position so no

visual alignment of marks is

necessary. Tighten the

locknut.

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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 operation in hilly country or in muddy

terrain.

1. Always maintain brake fluid level as

recommended (see page 35).

2. Check the brake system for fluid

leaks.

3. Check the brakes for excessive travel

or spongy feel.

4. Check the friction pads for wear,

damage and looseness.

5. Check the security and surface

condition of the disc.

NOTE: Install new brake pads when pads

3/64″ (.1 cm)

are worn to 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.

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

the all-wheel single lever system.

The hydraulic auxiliary brake system requires no adjustment.

Always maintain the brake fluid level as recommended. See page 38.

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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

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.

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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

and locate 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 front two bolts to 10-12 ft. lbs. (14-17 Nm), then torque

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

bolts.

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

Carburetor

IMPORTANT: Your Polaris ATV is calibrated at the factory for

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

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

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

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

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

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

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

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

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

NOTE: Continuous operation of the engine without proper jetting

when required can cause poor performance, overheating or

engine damage. See your Polaris dealer for more information

about jetting the ATV for conditions in your area.

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 lock

the parking brake.

3. Adjust the carburetor idle screw (1)

either in or out until the desired idle

RPM is reached. Turn the screw in

(clockwise) to raise RPM. Turn the

screw out (counterclockwise) to

lower RPM.

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

engines:

S For improving cold weather start and reducing audible detonation

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

screw clockwise.

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

be adjusted for smoother operation by turning the screw counter-

clockwise for approximately 2 turns.

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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. Place the transmission in gear and lock the parking brake.

WARNING

Improperly installed wheels can adversely affect tire wear and

vehicle handling, which can result in serious injury or death.

Always ensure that all nuts are torqued to specification. Do not

service axle nuts that have a cotter pin installed. See your

Polaris dealer.

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

outside and the rotation arrows on the tire pointing toward forward

rotation.

3. Install the wheel nuts and finger tighten. On vehicles with tapered

rear wheel nuts, make sure the tapered ends of the nuts fit into the

tapers on the wheels.

4. Lower the vehicle to the ground.

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

specifications chart.

Wheel Nut Torque Specifications

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

loosened for maintenance service.

Item

Specification

27 ft. lbs. (36.5 Nm)

50 ft. lbs. (68 Nm)

Front Wheel Nuts

Rear Wheel Nuts

Front

Rear

50 ft. lbs.

(68 Nm)

27 ft. lbs.

(36.5 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

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.

1. Always inspect the drive chain prior to operating the vehicle.

Check for damaged or missing o-rings or damaged rollers.

2. Check for correct slack adjustment.

3. Maintain the stone guard to rear sprocket clearance at 1/8″ (.3 cm).

4. Regularly lubricate the drive chain with Polaris chain lube or SAE

80-90 lube. See page 106 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. Don’t use a high pressure washer or gasoline

to clean the drive chain.

Cylinder Head/Cylinder Base Fastener

Have your dealer check the ATV cylinder head and cylinder base

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

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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. 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. Loosen the chain guide.

2. Loosen the two eccentric

locking bolts (1).

3. Loosen the caliper mounting

bolt located on the left side

of the swing arm.

4. 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

1. 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).

2. 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.

3. Tighten the caliper mount bolt to 15 ft. lbs. (20 Nm).

4. Remove the pin punch.

5. 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.

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

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

7. Reinstall the chain guard if applicable.

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MAINTENANCE AND LUBRICATION

Filter Systems

Air Filter Removal and Service

1. Remove the ATV seat.

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

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

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

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

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

if needed.)

Air Filter Installation

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

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

fully seated in the air box.

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

occur.

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

seated properly, then snap the clips onto the cover.

5. Reinstall the ATV seat.

Air Filter Cleaning

Check and replace the air filter at the intervals outlined in the Periodic

Maintenance Chart beginning on page 65.

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

emergency situation, however, you may clean the main filter

if you observe the following practices.

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

the clean air side of the filter.

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

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

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

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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 front cover and unplug the light harness.

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

retention screw.

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

bulb from the housing.

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

screw. Reinstall the rubber cap.

5. Reconnect the light harness and reinstall the cover.

6. Adjust the headlight aim if necessary.

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MAINTENANCE AND LUBRICATION

Lights

Headlight Adjustment

1. Position the vehicle on

a level surface with the

headlight approximately

25 ft. (7.6 m) from a

flat wall.

2. Measure the distance

from the floor to the

center of the headlight

and make a mark on the

wall at the same height.

3. Start the engine and

turn on the headlight.

4. Observe the headlight

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

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

NOTE: Include rider weight on the seat when measuring.

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

screws (1):

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

and to the left.

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

up and to the right.

S Turning the bottom screw clockwise adjusts the light upward.

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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). Apply

dielectric grease to the socket

and install the new lamp.

3. Test the taillight/brakelight to

see that it’s working.

4. Reinstall the gasket and lens cover.

Indicator Lamp Replacement

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

the indicator panel.

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

1/4 turn counterclockwise.

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

indicator panel housing.

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

5. Reassemble the pod or front cover.

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MAINTENANCE AND LUBRICATION

Spark Plugs

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

specifications section beginning on page 103 for the recommended spark

plug type and gap.

CAUTION

Using non-recommended spark plugs can result in serious engine

damage. Always use Polaris-recommended spark plugs.

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

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

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

check the spark plug for correct color.

WARNING

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

protective gloves when removing a spark plug for inspection.

1. Normal

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

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

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

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

overheating, caused by use of an improper spark plug or

incorrect carburetion adjustments.

2. Wet Fouled

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

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

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

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

incorrect carburetion adjustments.

Spark Plug Removal and Replacement

1. Remove the spark plug cap.

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

spark plug counterclockwise to remove.

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

lbs. (19 Nm).

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MAINTENANCE AND LUBRICATION

Vehicle Immersion

CAUTION

If your vehicle becomes immersed, major engine damage can

result if the machine is not thoroughly inspected. Take the

vehicle to your dealer before starting the engine.

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

the steps outlined below.

1. Move the ATV to dry land or at the

very least, to water below the foot

rests.

2. Check the airbox for any water. Drain

and dry it if water is present.

3. Turn the fuel valve off.

4. Remove the spark plug.

5. Remove the bowl drain (1).

6. Remove the crankcase drain screw at

the left front of the engine bottom.

7. Turn the engine over several times

using the electric start.

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

9. Reinstall the bowl drain.

10. Reinstall the crankcase drain screw.

11. Turn the fuel valve on.

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

procedure.

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

whether you succeed in starting it or not.

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

on page 95 for drying out the PVT.

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MAINTENANCE AND LUBRICATION

Spark Arrestor

WARNING

Failure to heed the following warnings while servicing the spark

arrestor could result in serious injury or death.

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

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

components to cool sufficiently before proceeding.

Remove any combustible materials from the area. Wear eye

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

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

enclosed area. Exhaust contains poisonous carbon monoxide

gas. Never go under the vehicle while it’s inclined.

1. Remove the arrestor clean-out

plug (1) from the bottom of the

muffler.

2. Place the transmission in 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.

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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 recoil handle must be

behind the heat shield for it to seal

properly.

The drain screw is located at the bottom of the recoil housing. Use a

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

draining the housing.

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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.

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MAINTENANCE AND LUBRICATION

PVT System

WARNING

Failure to comply with the instructions in this warning can result in

severe injury or death.

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

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

The PVT system has been precision balanced. Any modification

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

additional loads on components.

The PVT system rotates at high speeds, creating large amounts

of force on clutch components. Extensive engineering and

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

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

make sure this system remains safe:

Always follow all recommended maintenance procedures. See

your dealer as outlined in the owner’s manual.

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

not install it in any other product.

Always make sure the PVT housing is securely in place during

operation.

PVT Drying

There may be some instances when water is accidently ingested into

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

operating:

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

drain plug.

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

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

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

than 10 seconds.

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

transmission to the lowest available range.

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

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

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MAINTENANCE AND LUBRICATION

Battery

WARNING

Improperly connecting or disconnecting battery cables can result

in an explosion and cause serious injury or death. When

removing the battery, always disconnect the negative (black)

cable first. When reinstalling the battery, always connect the

negative (black) cable last.

Battery Removal

1. Disconnect the battery hold-down strap and remove the battery cover.

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

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

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

97 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.

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MAINTENANCE AND LUBRICATION

Battery

Battery Storage

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

remove the battery from the vehicle, ensure that it’s fully charged, and

store it out of the sun in a cool, dry place. Check battery voltage each

month during storage and recharge as needed to maintain a full charge.

NOTE: Battery charge can be maintained by using a Polaris Battery

Tendert charger (PN 2871076) or by charging about once a

month to make up for normal self-discharge. Battery

Tendert can be left connected during the storage period,

and will automatically charge the battery if the voltage drops

below a pre-determined point.

Battery Charging

The following battery charging instructions apply only to the

installation of a sealed battery. Read all instructions before proceeding

with the installation of this battery.

The sealed battery is already filled with electrolyte and has been sealed

and fully charged at the factory. Do not ever pry the sealing strip off or

add any other fluid to this battery.

The single most important thing about maintaining a sealed battery is

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

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

DC voltage.

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 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 may explode, causing severe injury or

death. Always watch charging times carefully. Stop charging if the

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

resuming charging.

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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

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MAINTENANCE AND LUBRICATION

Cleaning and Storage

See page 106 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, warning labels and decals.

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.

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MAINTENANCE AND LUBRICATION

Cleaning and Storage

Storage Tips

See page 106 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.

Air Filter / Air Box

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

box and drain the sediment tube.

Recoil Housing

Remove the recoil housing drain plug and drain any moisture.

Fluid Levels

Inspect the following fluid levels and change if necessary: engine oil;

transmission oil; brake fluid (change every two years or as needed if

fluid looks dark or contaminated).

100

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MAINTENANCE AND LUBRICATION

Cleaning and Storage

Storage Tips

See page 106 for the part numbers of Polaris products.

Engine

Use Polaris Fogging Oil and follow the directions on the can.

If you choose not to use Polaris Fogging Oil, perform the following

procedure.

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

slightly rearward.

2. Remove the spark plug. Rotate the piston to BDC and pour

approximately two ounces of the recommended oil into the

cylinder. Reinstall the spark plug.

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

the cap onto the plug.

4. With the ignition off, turn the engine over several times using the

recoil starter. This will ensure coverage of the piston rings,

cylinder walls and crankshaft bearings.

5. Treat the fuel system with Polaris Carbon Clean.

6. If Polaris fuel system additive is not used, fuel tank, fuel lines, and

carburetor should be completely drained of gasoline.

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.

Battery Storage

Remove the battery from the vehicle and ensure that it’s fully charged

before placing it in storage. See page 97 for instructions.

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.

101

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MAINTENANCE AND LUBRICATION

Cleaning and Storage

Chrome Wheel Care (if equipped)

Proper maintenance will protect chrome wheels from corrosion,

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

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

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

painted surfaces.

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

grade chrome polish.

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

polished chrome wheel. Choose a product suitable for chrome

finishes. Read and follow the product labels and instructions.

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

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

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

corrosive elements.

Removing Corrosion

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

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

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

outlined above.

Transporting an ATV

Follow these procedures when

transporting an ATV.

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 and securely.

4. Always tie the frame of the ATV to

the transporting unit securely using

suitable straps or rope. The rack,

bumper or handlebars do not offer

enough support for tie-down while

transporting the unit.

5. Always place the transmission in gear

and lock the parking brake.

102

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SPECIFICATIONS

2005 Trail Blazer

Capacities

Body Style

Gen III

Gross Vehicle Weight

Fuel Capacity

Engine Oil

765 lbs. (347 kg)

3.5 U.S. gal. (13.2 l)

2 qts. (1.89 l)

Transmission Oil

11.3 oz. (.33 l)

Front Rack (Accessory)

(Maximum Capacity)

30 lbs. (13.6 kg)

Rear Rack (Accessory)

Tongue Weight

Tow Hitch

60 lbs. (27.2 kg)

85 lbs. (38.5 kg)

Accessory

Tow Capacity

Turn Radius

Ground Clearance

Height

850 lbs. (385.5 kg)

63 in. (160 cm)

5.5 (14 cm)

47 in. (119.4 cm)

75 in. (190.5 cm)

34 in. (86.4 cm)

Length

Seat Height

Dry Weight

461 lbs. (209.1 kg)

Wheel Base

Width

48 in. (121.9 cm)

46 in. (116.8 cm)

Engine & Cooling

Engine Model Number / Type

Lubrication

EC-25PFE-154 / 2 Cycle, Single Cylinder

Oil Injection

Bore x Stroke

Displacement

Compression Ratio

Engine Cooling

Alternator Output

Carburetion

72 x 60

244cc

6.1/1 Effective

Air

150 watts @ 4000 RPM

1/VM30SS

Main Jet

130 (hex)

Pilot Jet

Needle Jet

0-4 (169)

Pilot Screw

1.0

Jet Needle

5DP7-3

Ignition

CDI

Timing

25° ± 3° @ 3000

NGK BR8ES / .028 in. (.7 mm)

Spark Plug Type / Gap

103

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SPECIFICATIONS

2005 Trail Blazer

Drive System

PVT

Drive System Type

Shift Type

Side Lever (F-N-R)

Not Applicable

3.05/1

Gear Reduction - Low

Gear Reduction - Reverse

Gear Reduction - Forward

Front Drive (ratio)

Final Drive (ratio)

Center Drive (ratio)

Drive Chain

2.68/1

Not Applicable

11/36 76P

Not Applicable

520 O-Ring

23 x 7-10 (4 psi)

22 x 11-10 (3 psi)

Front Tire

Rear Tire

Suspension and Brakes

McPherson Strut w/8.2″ (20.8 cm) travel

Front Suspension

Rear Suspension

Shock Adjustment

Front Brake

Progressive Rate w/10.5″ (26.7 cm) travel

CAM

Hydraulic Disc

Hydraulic lock, all wheel

Features

Rear Brake

Auxiliary Brake

Park Brake

Headlight

1 Single Beam (55 w)

8.26 w

Taillight

Brake Light

26.9 w

Battery

12V 14 AH

Accessory

DC Plug-In (Rear)

DC Socket (Forward)

Electric Start

High Temp Indicator

Windshield

Accessory

Standard

Not Available

Accessory

Low Oil Light

Neutral Indicator

Reverse Indicator

Speedometer

Fuel Gauge

Standard

Accessory

Standard

Tool Kit

Standard

104

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SPECIFICATIONS

2005 Trail Blazer

Jetting Chart

Altitude

Ambient

Temperature

Below 0°F

(Below --18°C)

0° to 40°F

(--18°C to

+5°C)

+40° to +80°F

(+5°C to

+80°F & Above

(+26°C &

+26°C)

Above)

0-900

Meters

(Feet)

150

140

125

115

140

130

120

110

130

120

110

100

120

110

100

(0-3000)

900-1800

(3000-6000)

1800-2700

(6000-9000)

2700-3700

(9000-12000)

Turn air screw out 1/2 turn CCW from seat. Raise needle clip 1 position to lower jet needle.

Clutching Chart

Altitude

Shift

Weight

Drive Clutch Driven Clutch

Helix/Spring

Setting

Spring

Meters

(Feet)

0-1800

(0-6000)

Blue/Green

(7041157)

Red

(7041198)

40°

(5131446)

2+2

(5630514)

1800-3700

(6000-12000)

Blue/Green

(7041157)

Red

(7041198)

40°

(5131446)

2+2

(5630515)

105

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POLARIS PRODUCTS

Part No.

Description

Engine Lubricant

2870791

2871098

2871097

2871721

2871722

2874438

2874439

Fogging Oil (12 oz. Aerosol)

Premium Blue 2-Cycle Mineral Oil (qt.)

Premium Blue 2-Cycle Mineral Oil (gal.)

Premium Gold Synthetic 2-Cycle Oil (qt.)

Premium Gold Synthetic 2-Cycle Oil (gal.)

VES II Synthetic 2-Cycle Oil (qt.)

VES II Synthetic 2-Cycle Oil (gal.)

Gearcase / Transmission Lubricants

Premium AGL Synthetic Gearcase Lube (qt.)

Premium AGL Synthetic Gearcase Lube (gal.)

Pump for Gallon Jug

2873602

2873603

2870465

Grease / Specialized Lubricants

Premium All Season Grease (3 oz. cartridge)

Premium All Season Grease (14 oz. cartridge)

Starter Drive Grease

2871322

2871423

2871460

2871312

2871329

2872073

2872348

Grease Gun Kit

Dielectric Grease (Nyogelt)

Chain Lube (6.25 oz. aerosol)

Chain Lube (16 oz. aerosol)

Additives / Miscellaneous

Brake and Clutch Cleaner

Carbon Clean Plus (12 oz.)

Fuel Stabilizer (16 oz.)

DOT3 Brake Fluid

2872889

2871326

2870652

2870990

2872893

Engine Degreaser

106

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TROUBLESHOOTING

Drive Belt and Cover Problems

Possible Cause

Solution

Driving the ATV onto a

pickup or tall trailer in

high range.

Avoid stopping on the ramp or creeping slowly up the

ramp. These practices may slip the clutch and belt.

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 55.

Driving at low RPM or

low ground speed (at

approximately 3-7 MPH).

Drive at a higher speed. Avoid creeping.

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.

Install a one tooth smaller counter shaft sprocket.

Stuck in mud or snow.

Carefully use fast, aggressive throttle application to en-

gage clutch. WARNING: Excessive throttle may cause

loss of control and vehicle overturn.

Climbing over large ob-

Carefully use fast, brief, aggressive throttle application to

jects from a stopped posi- engage clutch. WARNING: Excessive throttle may cause

tion.

loss of control and vehicle overturn.

Belt slippage from water Dry out the PVT as outlined on page 95. Inspect clutch

or snow ingestion into the seals for damage if repeated leaking occurs.

PVT system.

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.

107

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TROUBLESHOOTING

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

solutions using the following charts.

Engine Doesn’t Turn Over

Possible Cause

Solution

Low battery voltage

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

108

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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

109

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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 engine exterior

See your Polaris dealer

110

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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.

111

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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.

112

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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

113

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INDEX

Accessories . . . . . . . . . . . . . . . . . . . 64

Adjustments . . . . . . . . . . . . . . . . 73-85

FEATURES . . . . . . . . . . . . . . . . 32-43

Filter Systems . . . . . . . . . . . . . . . . . 86

Front Wheel Hub Tightening . . . . . 82

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

Fuel Safety . . . . . . . . . . . . . . . . . . . 40

Fuel Stabilizer . . . . . . . . . . . . . . . . 100

Fuel Tank . . . . . . . . . . . . . . . . . . . . 39

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

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

Air Filter . . . . . . . . . . . . . . . . . . . . . 86

Auxiliary Brake . . . . . . . . . . . . 38, 75

Battery . . . . . . . . . . . . . . . . . . . . 96-98

Battery Charging . . . . . . . . . . . . . 97-98

Battery Installation . . . . . . . . . . . . . 96

Battery Removal . . . . . . . . . . . . . . . 96

Battery Storage . . . . . . . . . . . . 97, 102

Brake Lever . . . . . . . . . . . . . . . . . . 36

Brakes . . . . . . . . . . . . . . . . . . . . 35, 75

Break-In Period . . . . . . . . . . . . . . 44-45

Gear Selector . . . . . . . . . . . . . . . . . . 42

Handlebars . . . . . . . . . . . . . . . . . . . 78

Hauling Cargo . . . . . . . . . . . . . . . 60-61

Headlight Adjustment . . . . . . . . . . . 88

Headlight Lamp Replacement . . . . . 87

Camber and Caster . . . . . . . . . . . . . 77

Carburetor . . . . . . . . . . . . . . . . . . . . 79

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

Chrome Wheel Care . . . . . . . . . . . 102

Cleaning and Storage . . . . . . . . 99-102

Cleaning the ATV . . . . . . . . . . . . . . 99

Clutching Chart . . . . . . . . . . . . . . . 105

CONTROLS . . . . . . . . . . . . . . . . 32-43

Corrosion, Removing . . . . . . . . . . 102

Cylinder Head/

Indicator Lamp Replacement . . . . . 89

Indicator Lights . . . . . . . . . . . . . . . . 34

Jetting Chart . . . . . . . . . . . . . . . . . 105

Cylinder Base Fastener . . . . . . 83

K-Turn . . . . . . . . . . . . . . . . . . . . . . 55

Drive Chain . . . . . . . . . . . . . . . . . . 83

Driving Downhill . . . . . . . . . . . . . . 54

Driving in Reverse . . . . . . . . . . . . . 59

Driving on Slippery Surfaces . . . . . 51

Driving Over Obstacles . . . . . . . . . . 58

Driving Procedures . . . . . . . . . . . . . 49

Driving Safely . . . . . . . . . . . . . . . 49-62

Driving Through Water . . . . . . . . 56-57

Driving Uphill . . . . . . . . . . . . . . . . 52

Light Switches . . . . . . . . . . . . . . . . 34

Lights . . . . . . . . . . . . . . . . . . . . . 87-89

Lubricants, 2-Cycle . . . . . . . . . . . . . 70

Lubrication Recommendations . . 69-72

Main Switch . . . . . . . . . . . . . . . . . . 32

MAINTENANCE AND

LUBRICATION . . . . . . . . 64-102

Maintenance Record . . . . . . . . . . . . 68

Making Turns . . . . . . . . . . . . . . . . . 50

Electrical Switches . . . . . . . . . . . . . 32

EMISSION CONTROL SYSTEMS 63

Engine Fogging . . . . . . . . . . . . . . 101

Engine Oil Check . . . . . . . . . . . . . . 71

Equipment Modifications . . . . . . . . 12

Noise Emission Control System . . . 63

114

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INDEX

Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Oil Injection Tank . . . . . . . . . . . . . . 41

Oil Pump Adjustment . . . . . . . . . . . 74

Oil Pump Bleeding . . . . . . . . . . . . . 73

OPERATION . . . . . . . . . . . . . . . 44-62

Operator Safety . . . . . . . . . . . . . . . 8-27

Override Switch . . . . . . . . . . . . . . . 32

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

Taillight/Brakelight

Lamp Replacement . . . . . . . . . 89

Throttle Cable Freeplay . . . . . . . . . . 78

Throttle Lever . . . . . . . . . . . . . . . . . 33

Tire Tread Depth . . . . . . . . . . . . . . . 82

Toe Alignment . . . . . . . . . . . . . . . . 76

Transmission Gear Selector . . . . . . . 42

Transmission Oil Change . . . . . . . . 72

Transmission Oil Check . . . . . . . . . 72

Transporting an ATV . . . . . . . . . . 102

TROUBLESHOOTING . . . . . 107-110

Turning Around on a Hill . . . . . . . . 55

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

Parking on an Incline . . . . . . . . . . . 62

Periodic Maintenance Chart . . . . 64-67

POLARIS PRODUCTS . . . . . . . . 106

Pre-Ride Inspection . . . . . . . . . . . . . 46

PVT Drying . . . . . . . . . . . . . . . . . . 95

PVT System . . . . . . . . . . . . . . . . 94-95

USFS Approved Spark Arrestor . . . 63

VEHICLE IDENTIFICATION

Rear Drive Chain Slack . . . . . . . . 84-85

Rear Spring . . . . . . . . . . . . . . . . . . . 77

Recoil Housing . . . . . . . . . . . . . . . . 93

Recoil Starter . . . . . . . . . . . . . . . . . 43

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

Vehicle Immersion . . . . . . . . . . . . . 91

WARRANTY . . . . . . . . . . . . . 111-113

Washing the ATV . . . . . . . . . . . . . . 99

Waxing the ATV . . . . . . . . . . . . . . . 99

Safe Riding Gear . . . . . . . . . . . . . . . 31

SAFETY . . . . . . . . . . . . . . . . . . . . 8-31

Safety Decals and Locations . . . . 28-30

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

Wheel Installation . . . . . . . . . . . . . . 81

Wheel Nut Torque Specifications . . 81

Wheel Removal . . . . . . . . . . . . . . . 80

Safety Training . . . . . . . . . . . . . . . . .

Sidehilling . . . . . . . . . . . . . . . . . . . 53

Spark Arrestor . . . . . . . . . . . . . . . . . 92

Spark Plugs . . . . . . . . . . . . . . . . . . . 90

SPECIFICATIONS . . . . . . . . . 103-105

Starting a Cold Engine . . . . . . . . . . 47

Starting a Warm Engine . . . . . . . . . 48

Starting the Engine . . . . . . . . . . . 47-48

Steering Assembly . . . . . . . . . . . . . 77

Stop Switch . . . . . . . . . . . . . . . . . . . 32

Storage Tips . . . . . . . . . . . . . . 100-102

115

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