Polaris Offroad Vehicle 330 User Manual

Download from Www.Somanuals.com. All Manuals Search And Download.  
WARNING  
The engine exhaust from this product contains  
chemicals known to the State of California to cause  
cancer, birth defects or other reproductive harm.  
A card containing important ATV safety information should be attached  
to the owner’s manual on the next page. If you cannot locate this card,  
or if it has been removed, please call 1-800-342-3764 for assistance.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
S Snowmobiles  
S All-terrain vehicles (ATVs)  
S RANGER utility vehicles  
S Victory motorcycles  
We believe Polaris sets a standard of excellence for all utility and  
recreational vehicles manufactured in the world today. Many years of  
experience have gone into the engineering, design, and development of  
your Polaris vehicle, making it the finest machine we’ve ever  
produced.  
For safe and enjoyable operation of your vehicle, be sure to follow the  
instructions and recommendations in this owner’s manual. Your  
manual contains instructions for minor maintenance, but information  
about major repairs is outlined in the Polaris Service Manual and  
should be performed only by a Factory Certified Master Service Dealer  
(MSD) Technician.  
Your Polaris dealer knows your vehicle best and is interested in your  
total satisfaction. Be sure to return to your dealership for all of your  
service needs during, and after, the warranty period.  
We also take great pride in our complete line of apparel, parts and  
accessories, available through our online store at  
www.purepolaris.com. Have your accessories and clothing delivered  
right to your door!  
1
Download from Www.Somanuals.com. All Manuals Search And Download.  
Copyright 2007 Polaris Sales Inc. All information contained within this publication is  
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.  
2008 Trail Blazer 330 Owner’s Manual P/N 9921539  
2
Download from Www.Somanuals.com. All Manuals Search And Download.  
TABLE OF CONTENTS  
KNOW YOUR VEHICLE . . . . . . . . . . . . . . . . . . . . . 5  
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  
FEATURES AND CONTROLS . . . . . . . . . . . . . . . 31  
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41  
EMISSION CONTROL SYSTEMS . . . . . . . . . . . . 59  
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 60  
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 104  
POLARIS PRODUCTS . . . . . . . . . . . . . . . . . . . . 107  
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . 108  
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112  
MAINTENANCE LOG . . . . . . . . . . . . . . . . . . . . . 116  
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118  
3
Download from Www.Somanuals.com. All Manuals Search And Download.  
4
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
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. An  
ignition key can be duplicated only by ordering a Polaris key blank  
(using your key number) and mating it with one of your existing keys.  
The ignition switch must be replaced if all keys are lost.  
31XX  
1
2
Vehicle Model Number:  
Frame VIN (1):  
Engine Serial Number (right front side of engine crankcase):  
Key Number (2):  
5
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
Safety Training  
ATV safety training is a top priority for Polaris. When you purchased  
your new ATV, your dealer instructed you on the authorized ATV  
RiderCoursesm available to you and your eligible family members.  
This training is included in the purchase price of your ATV. Polaris  
strongly encourages you and your eligible family members who will be  
riding the ATV to take the ATV RiderCoursesm. You were also  
provided with printed materials that explain safe operating procedures.  
You should review this information on a regular basis.  
If you purchased a used Polaris ATV, you can take the ATV  
RiderCoursesm by calling ATV Enrollment Express at (800) 887-2887  
or by visiting www.atvsafety.org. Purchasers of a used Polaris ATV  
will be charged for this training.  
A Polaris ATV is an off-road vehicle. Familiarize yourself with all  
laws and regulations concerning the operation of the ATV in your area.  
We strongly advise you to strictly follow the recommended  
maintenance program outlined in your owner’s manual. This  
preventive maintenance program is designed to ensure that all critical  
components on your vehicle are thoroughly inspected at specific  
intervals.  
6
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
7
Download from Www.Somanuals.com. All Manuals Search And Download.  
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. Purchasers of a new Polaris ATV and their eligible family  
members are entitled to take the ATV RiderCoursesm. Contact ATV  
Enrollment Express at (800) 887-2887 or visit www.atvsafety.org for  
information on enrollment in the ATV RiderCoursesm.  
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.  
8
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
9
Download from Www.Somanuals.com. All Manuals Search And Download.  
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 visit  
www.cpsc.gov, visit www.atvsafety.org, 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.  
10  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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 ATV  
RiderCoursesm offered by Polaris through the SVIA. They should  
then regularly practice the skills learned in the course and the  
operating techniques described in the Owner’s Manual.  
For more information about the ATV RiderCoursesm contact ATV  
Enrollment Express at (800) 887-2887 or visit www.atvsafety.org.  
WARNING  
POTENTIAL HAZARD  
Failure to follow the age recommendations for this ATV.  
WHAT CAN HAPPEN  
Severe injury and/or death could occur if a child under the  
minimum age recommendation operates 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.  
11  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
12  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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 HAZA
Never operate the ATV on an
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.  
13  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
14  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
15  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
16  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
WARNING  
POTENTIAL HAZARD  
Failure to use extra  
caution when operating
excessively rough,  
slippery or loose terrain
WHAT CAN HAPPEN  
Operating on excessive
rough, slippery or loose  
terrain could cause loss
traction or loss of contro
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.  
17  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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 coul
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.  
18  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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 52.  
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.  
19  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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 54. 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.  
20  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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 54.  
21  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
22  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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 55), 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.  
23  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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 46.  
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.  
24  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
WARNING  
Leaving the keys in the ignition can lead to unauthorized use of  
the vehicle resulting in serious injury or death. Always remove  
the ignition key when the vehicle is not in use.  
WARNING  
After any overturn or accident, have a qualified service dealer  
inspect the entire vehicle for possible damage, including (but not  
limited to) brakes, throttle and steering systems.  
WARNING  
Safe operation of this rider-active vehicle requires good  
judgement and physical skills. Persons with cognitive or physical  
disabilities who operate this vehicle have an increased risk of  
overturn and loss of control, which could result in severe injury or  
death.  
CAUTION  
Exhaust system components are very hot during and after use of  
the vehicle. Hot components can cause serious burns and fire.  
Do not touch hot exhaust system components. Always keep  
combustible materials away from the exhaust system. Use  
caution when traveling through tall grass, especially dry grass.  
25  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
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.  
26  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Safety Decals and Locations  
Warning decals have been placed on the ATV for your protection. Read  
and follow the instructions of the decals on the ATV carefully. If any  
of the decals depicted in this manual differ from the decals on your  
ATV, always read and follow the instructions of the decals on the ATV.  
If any decal becomes illegible or comes off, contact your Polaris dealer  
to purchase a replacement. Replacement safety decals are provided by  
Polaris at no charge. The part number is printed on the decal.  
Discretionary Warning (1)  
WARNING  
1
S Never operate this vehicle on  
HILLS steeper than 25 degrees  
25°. To prevent flipover on  
hilly terrain, when going up or  
down, use throttle and brakes  
gradually.  
S REVERSE operation can be  
dangerous, even at low speeds.  
Steering becomes difficult. To  
prevent flipover, avoid sudden  
braking or sharp turns.  
2
S Use OVERRIDE for reverse  
speed limiter with caution. To  
prevent loss of control, never activate  
override button with open throttle.  
S PARKING BRAKE may relax when used  
for more than 5 minutes. When parking on grades, leave shift in forward.  
Clutch Cover Warning (2)  
WARNING  
NO STEP  
S Moving parts hazard under belt-clutch guard. To prevent serious injury, do  
not operate vehicle with guard removed.  
S Do not modify engine or clutch. Doing so can cause part failure, possible im-  
balance, and excessive engine RPM, which can result in serious injury or  
death.  
27  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Safety Decals and Locations  
General Warning (3)  
WARNING  
3
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:  
S without proper training or instruction  
S at speeds too fast for your skills or the  
conditions  
S on public roads -- a collision can occur with  
another vehicle  
S with a passenger -- passengers affect balance and steering and increase risk  
of losing control  
ALWAYS:  
S use proper riding techniques to avoid vehicle overturns on hills and rough  
terrain and in turns  
S avoid paved surfaces -- pavement may seriously affect handling and control  
LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS  
AND WARNINGS. IF OWNER’S MANUAL IS MISSING, CONTACT A POLARIS  
DEALER FOR A REPLACEMENT.  
28  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Safety Decals and Locations  
No Passenger Warning (4)  
WARNING  
5
4
NEVER ride as a passenger.  
Passengers can cause a  
loss of control, resulting in  
SEVERE INJURY or  
DEATH.  
6
Age 16 Warning (5)  
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.  
Tire Pressure/Load Warning (6)  
WARNING  
IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control  
resulting in SEVERE INJURY OR DEATH.  
TIRE PRESSURE IN PSI (KPa): FRONT 4 (27.6) REAR 3 (20.7)  
MAXIMUM WEIGHT CAPACITY 305 LBS. (138 KG).  
Reduce speed and allow greater distance for braking when carrying cargo.  
Overloading or carrying tall, off-center, or unsecured loads will increase your  
risk of losing control. Loads should be centered, carried as low as possible, and  
firmly secured to the racks. With dual racks, load distribution 1/3 front 2/3 rear is  
best. For stability on rough or hilly terrain, reduce speed and cargo. Do not  
block headlight. Be careful if load extends over the side of the rack.  
Read Owner’s Manual for more detailed loading information.  
29  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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  
Wearing a helmet can prevent a severe head  
injury. Whenever riding a Polaris vehicle,  
always wear a helmet that meets or exceeds  
established safety standards.  
Approved helmets in the USA and Canada  
bear a U.S. Department of Transportation  
(DOT) label.  
Approved helmets in Europe, Asia and  
Oceania bear the ECE 22.05 label.  
The ECE mark consists of  
2
a circle surrounding the  
letter E, followed by the  
distinguishing number of  
the country which has  
granted approval. The  
approval number and serial  
number will also be  
4
E
051039  
0006.031  
displayed on the label.  
2. Eye Protection  
Do not depend on eyeglasses or sunglasses for eye protection.  
Whenever riding a Polaris vehicle, always wear shatterproof goggles or  
use a shatterproof helmet face shield. Polaris recommends wearing  
approved Personal Protective Equipment (PPE) bearing markings such  
as VESC 8, V--8, Z87.1, or CE. Make sure protective eye wear is kept  
clean.  
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 sturdy over-the-calf boots with low heels.  
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.  
30  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FEATURES AND CONTROLS  
Electrical Switches  
3
1
2
WARNING  
Activating the override switch while the throttle is open can cause  
loss of control, resulting in severe injury or death. Do not activate  
the override switch while the throttle is open.  
Override Switch (1) (Reverse Speed Limiter) -  
OFF RUN OFF  
This vehicle is equipped with a reverse speed  
limiter system. To gain additional power while  
backing, depress the override switch.  
3
Main Switch (2) - To start the engine, slide the stop  
switch to the center RUN position and turn the main key switch  
clockwise past the ON position. Release the key when the engine starts.  
NOTE: Turn off the main switch to end all electrical power to the  
vehicle, including the lights.  
WARNING  
Leaving the keys in the ignition can lead to unauthorized use of  
the vehicle resulting in serious injury or death. Always remove  
the ignition key when the vehicle is not in use.  
Engine Stop Switch (3) - The engine will not start or run when the  
switch is in its OFF position. Its purpose is to provide the operator  
with a quick means of engine shutdown in case of an emergency. To  
stop the engine, slide the stop switch either right or left to the OFF  
position.  
NOTE: Turning off the engine stop switch will shut off all electrical  
power to the vehicle, including the lights.  
31  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FEATURES AND CONTROLS  
Light Switches  
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.  
Use the light switch (1) 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  
1
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
2
3
1. Transmission Neutral Indicator  
2. Transmission Reverse Indicator  
3. High Temp Warning (displays if engine overheats)  
32  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FEATURES AND CONTROLS  
Throttle Lever  
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.  
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  
1
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.  
33  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FEATURES AND CONTROLS  
Brake Lever  
WARNING  
Operating the ATV with a spongy brake lever can result in loss of  
braking, which could cause an accident. Never operate the ATV  
with a spongy-feeling brake lever.  
1
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.  
34  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FEATURES AND CONTROLS  
Brakes  
1
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.  
2
The fluid level can be seen through  
an indicator window (2) on the top  
of the master cylinder. This “eye”  
will appear dark when the fluid level  
is full. When fluid needs to be  
added, the eye will be clear.  
WARNING  
An over-full master cylinder may cause brake drag or brake  
lock-up, which could result in serious injury or death. Maintain  
brake fluid at the recommended level. Do not overfill.  
NOTE: When checking the fluid level, the ATV must be on level  
ground with the handlebars straight. If the fluid level is low  
add DOT 4 brake fluid only. DO NOT OVERFILL. See page  
107 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.  
35  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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
1. Squeeze and release the brake lever two or  
three times, then squeeze and hold.  
2. Push the park brake lock (1)  
forward to engage the brake.  
Release the brake lever.  
3. To release the parking brake lock,  
squeeze and release the brake  
lever. It will return to its unlocked  
position.  
Important Safeguards  
S The parking brake may relax if left on for a long period of time. Al-  
ways block the wheels to prevent rolling.  
S Always block the wheels on the downhill side of the ATV if leaving  
it parked on a hill. Another option is to park the ATV in a sidehill  
position.  
S Never depend on the parking brake alone if the ATV is parked on a  
hill. Always block the wheels to prevent rolling.  
36  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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 foot brake (1), is  
located on the inside of the right  
floorboard and is operated by the  
right foot. The auxiliary brake  
serves as a backup to the main  
brake system if the main system  
becomes inoperative.  
If the rear wheels slide while  
using the auxiliary brake, reduce  
brake pedal pressure to brake the  
rear wheels without skidding.  
1
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.  
37  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FEATURES AND CONTROLS  
Choke  
The choke assists in starting a cold engine. Refer to the engine starting  
procedure on page 43 for correct choke and throttle settings during  
starting.  
Fuel Valve  
RES  
The fuel valve (1) is located on the left side of  
the vehicle, below the fender. It has three  
positions:  
OFF  
OFF: For vehicle storage and when transporting.  
ON: For normal operation.  
ON  
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  
2
reserve gas. Always refill the  
gas tank as soon as possible  
after using the reserve supply.  
1
Always return the valve to the ON  
position after refueling.  
Fuel Tank  
Remove the fuel tank cap (2) to add fuel to  
the fuel tank. Use either leaded or  
unleaded gasoline with a minimum pump  
octane number of 87=(R+ M/2) octane. Do  
not use E--85 fuel.  
Refer to the specifications section at the  
rear of this manual for tank capacity.  
Fuel Filter  
The in-line fuel filter should be replaced by your dealer after every 100  
hours of operation, or annually. Do not attempt to clean the fuel filter.  
38  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FEATURES AND CONTROLS  
Automatic Transmission Gear Selector  
The transmission gear selector (1)  
is located on the right side of the  
vehicle.  
1
F
F: Forward  
N: Neutral  
R: Reverse  
N
R
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.  
39  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
2
1
Polaris 4-cycle engines are  
equipped with automatic  
decompressors. This makes recoil  
starting possible by reducing the amount of compression during  
starting. The decompressor senses when the engine is spinning fast  
enough to start and restores compression when running.  
1. Position the vehicle on a level surface and lock the parking brake  
(see page 36).  
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 43.  
4. Grasp the recoil starter rope handle (2) firmly and pull slowly so  
you can feel the engine strokes.  
NOTE: Every other stroke will be a “compression stroke” and will  
make the rope harder to pull. When a compression stroke is  
found, continue pulling the rope just until the engine rolls past  
the stroke, then stop pulling immediately.  
5. Allow the recoil rope to rewind into the recoil assembly, then pull  
the rope abruptly and forcefully to start the engine.  
6. Repeat steps 4-5 if necessary.  
CAUTION  
Extending the recoil starter rope until it stops can cause damage  
to the recoil assembly. Do not extend the starter rope so far that  
it stops.  
If the starter rope handle is not seated properly, water may enter  
the recoil housing and damage components. Make sure the  
handle is fully seated on the recoil housing, especially when  
traveling in wet areas.  
40  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Break-In Period  
The break-in period for your new Polaris ATV is the first ten hours of  
operation, or the time it takes to use the first two full tanks of gasoline.  
No single action on your part is as important as following the  
procedures for a proper break-in. Careful treatment of a new engine  
and drive components will result in more efficient performance and  
longer life for these components.  
CAUTION  
Excessive heat build-up during the first three hours of operation  
will damage close-fitted engine parts and drive components. Do  
not operate at full throttle or high speeds during the first three  
hours of use.  
Engine and Drivetrain Break-in  
1. Fill the fuel tank with gasoline (see page 38).  
2. Check the oil level (see page 66). Add the recommended oil as  
needed.  
3. Drive slowly at first. Select an open area that allows room to  
familiarize yourself with vehicle operation and handling.  
4. Vary throttle positions. Do not operate at sustained idle.  
5. Perform regular checks on fluid levels, controls and areas outlined  
on the daily pre-ride inspection checklist. See page 42.  
6. Pull only light loads.  
7. During the break-in period, change both the oil and the filter at 20  
hours or one month, whichever comes first.  
PVT Break-in (Clutches/Belt)  
A proper break-in of the clutches and drive belt will ensure a longer  
life and better performance. Break in the clutches and belt by  
operating at slower speeds during the break-in period as recommended.  
Pull only light loads. Avoid aggressive acceleration and high speed  
operation during the break-in period.  
41  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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  
34, 71  
35  
Auxiliary brake  
Front suspension  
Rear suspension  
Steering  
Ensure proper operation  
Inspect, lubricate if necessary  
Inspect, lubricate if necessary  
Ensure free operation  
72  
64  
64  
--  
Tires  
Inspect condition and pressure  
Inspect, ensure fastener tightness  
78  
Wheels / fasteners  
77  
Frame nuts, bolts, fasteners Inspect, ensure tightness  
--  
Fuel and oil  
Ensure proper levels  
Ensure proper level  
66  
Coolant level (if applicable)  
--  
Coolant hoses (if applicable) Inspect for leaks  
--  
Throttle  
Ensure proper operation  
33, 73  
31, 32  
31  
Indicator lights / switches  
Engine stop switch  
Drive chain  
Ensure operation  
Ensure proper operation  
Check condition / slack, lubricate as  
needed  
79, 80  
Air filter, pre-filter  
Air box sediment tube  
Headlamp  
Inspect, clean  
84  
--  
Drain deposits whenever visible  
Check operation, apply Polaris dielec-  
tric grease when lamp is replaced  
82  
Brake light / tail lamp  
Riding gear  
Check operation, apply Polaris dielec-  
tric grease when lamp is replaced  
83  
30  
Wear helmet, goggles, protective  
clothing  
42  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Starting the Engine  
WARNING  
Engine exhaust contains poisonous carbon monoxide and can  
cause loss of consciousness resulting in severe injury or death.  
Never run an engine in an enclosed area.  
1. Position the vehicle on a level  
surface.  
1
2. Place the transmission in  
neutral.  
3. Lock the parking brake.  
NOTE: The starter interlock will  
prevent the engine from  
starting if the  
transmission is in gear  
and the brake is not  
engaged.  
2
4. Turn the fuel valve on.  
5. Sit on the vehicle.  
NOTE: Do not use the choke if starting a warm engine. Excessive  
use of the choke can cause the spark plug to become wet  
fouled.  
6. If the engine is cold, pull the choke knob out until it stops (1).  
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.  
NOTE: If the knob doesn’t stay where positioned, increase the  
tension by rotating the tension adjusting nut (2) clockwise.  
43  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Starting the Engine  
7. Move the engine stop switch to RUN.  
NOTE: Do not press the throttle while starting the engine.  
8. Turn the ignition key past the ON position to engage the starter.  
Activate the starter for a maximum of five seconds, releasing the  
key when the engine starts.  
9. If the engine does not start, release the key and wait five seconds.  
Activate the starter for another five seconds. Repeat this procedure  
until the engine starts.  
NOTE: If a warm engine has cooled to a point where it does not  
readily start, intermittent use of the choke button (pulled half  
way out) may be necessary. If the engine is over-choked  
when warm, depress the throttle lever fully while cranking to  
aid in starting. 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.  
10. If the engine slows, position the choke knob half way in to allow  
proper engine warm up. Vary the engine RPM slightly with the  
throttle to aid in warm-up. When the engine idles smoothly, push  
the choke completely in.  
CAUTION  
Operating the vehicle immediately after starting could cause  
engine damage. Allow the engine to warm up for several minutes  
before operating the vehicle.  
44  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
45  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Driving Safely  
Hauling Cargo  
2/3  
1/3  
Accessory racks and hitches are available from your Polaris dealer.  
Always read and understand the load distribution warnings on all  
warning labels, and never exceed the specified weight capacities for the  
vehicle.  
Maximum Towing Capacities  
Refer to the specifications at the rear of this manual for towing  
capacities. When towing, reduce the rear rack cargo load capacity by  
the amount of trailer tongue weight.  
Never tow any trailer on a grade steeper than 15°.  
46  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Driving Safely  
Hauling Cargo  
WARNING  
Hauling cargo improperly can alter vehicle handling and may  
cause loss of control or brake instability and result in serious  
injury or death. Always follow these precautions when hauling  
cargo:  
S REDUCE SPEED AND ALLOW GREATER 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.  
47  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Driving Safely  
Making Turns  
Your Polaris ATV is equipped with a solid rear axle, which drives both  
rear wheels equally at all times. This means that the wheel on the  
outside of the turn must travel a greater distance than the inside wheel  
when turning and the inside tire must slip traction slightly.  
To make a turn, steer in the direction of the turn, leaning your upper  
body to the inside of the turn while supporting your weight on the  
outer footrest. This technique alters the balance of traction between the  
rear wheels, allowing the turn to be made smoothly. The same leaning  
technique should be used for turning in reverse.  
NOTE: Practice making turns at slow speeds before attempting to  
turn at faster speeds.  
WARNING  
Turning at sharp angles or at excessive speeds can result in  
vehicle overturn and lead to serious injury. Avoid turning at sharp  
angles. Never turn at high speeds.  
48  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
49  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Driving Safely  
Driving Uphill  
25_ Maximum  
WARNING  
Braking and handling are greatly affected when operating in hilly  
terrain. Improper procedure could cause loss of control or  
overturn and result in serious injury or death.  
Avoid climbing steep hills (25_ maximum).  
Use extreme caution when operating on hills, and follow proper  
operating procedures outlined in the owner’s manual.  
50  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Driving Safely  
Driving Uphill  
Whenever traveling uphill, follow these precautions:  
1. Always travel straight uphill.  
2. Avoid steep hills (25_ maximum).  
3. Keep both feet on the footrests.  
4. Transfer your weight forward.  
5. Proceed at a steady rate of speed and throttle opening.  
6. Remain alert and be prepared to take emergency action.  
This may include quick dismounting of the vehicle.  
If all forward speed is lost:  
Keep your weight uphill.  
Apply the single lever brake, gradually. When fully stopped, apply the  
auxiliary brake as well, then lock the park brake.  
If the ATV begins rolling backwards:  
Keep your weight uphill. Never apply engine power. Never apply the  
auxiliary rear brake while rolling backwards.  
Apply the single-lever brake, gradually. When fully stopped, apply the  
auxiliary rear brake as well, and then lock the parking brake.  
Dismount on uphill side, or to either side if ATV is pointed straight  
uphill. Turn the ATV around and remount, following the procedure  
described on page 54.  
51  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
52  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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!  
53  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Driving Safely  
Turning Around on a Hill  
If the vehicle stalls while climbing a hill, never back it down the hill!  
Use the K-turn to turn around.  
8’ (2.4 m)  
1. Stop and lock the parking brake while keeping body weight uphill.  
2. Leave the transmission in forward and shut off the engine.  
3. Dismount on the uphill side of the vehicle, or on the left if the  
vehicle is pointing straight uphill.  
4. Staying uphill of the vehicle, turn the handlebars full left.  
5. While holding the 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.  
54  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Driving Safely  
Driving Through Water  
Your ATV can operate through wa
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.  
1
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 60. The following areas  
need special attention: engine oil, transmission oil, front and rear  
gearcases (if equipped), and all grease fittings.  
CAUTION  
Major engine damage can result if the vehicle is not thoroughly  
inspected after operation in water. Perform the services outlined  
in the maintenance chart.  
If your vehicle becomes immersed or is operated in water that  
exceeds the footrest level, take it to your dealer for service before  
starting the engine.  
NOTE: Avoid operating the vehicle through deep or fast-flowing  
water. If you cannot avoid water that exceeds the  
recommended maximum depth, go slowly, balance your  
weight carefully, avoid sudden movements, and maintain a  
slow and steady forward motion. Do not make sudden turns  
or stops, and do not make sudden throttle changes.  
If your vehicle becomes immersed, and it’s impossible to take it to a  
dealer before starting it, follow the steps described on page 87. Have  
the vehicle serviced by your dealer at the first opportunity.  
55  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
56  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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: This Polaris ATV is equipped with a reverse speed limiter.  
The override button should be used with caution as rearward  
vehicle speed is greatly increased. Do not operate at wide  
open throttle. Open the throttle just enough to maintain a  
desired speed.  
CAUTION  
Excessive throttle operation while in the speed limit mode may  
cause fuel to build in the exhaust, resulting in engine popping  
and/or engine damage.  
57  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Driving Safely  
Parking on an Incline  
Avoid parking on an incline if possible. If it’s unavoidable, follow  
these precautions:  
1. Turn the engine off.  
1. Place the transmission in gear.  
2. Set the parking brake.  
3. Always block the rear wheels on the downhill side. See  
illustration.  
4. Shut off the fuel supply.  
58  
Download from Www.Somanuals.com. All Manuals Search And Download.  
EMISSION CONTROL SYSTEMS  
Noise Emission Control System  
Do not modify the engine, intake or exhaust components, as doing so  
may affect compliance with U.S.A. EPA noise control requirements (40  
CFR 205) and local noise level requirements.  
Operation on Public Lands in the U.S.A.  
Your Polaris vehicle has a spark arrestor that was tested and qualified  
to be in accordance with the USDA Forest Service Standard 5100-1C.  
Federal law requires that this spark arrestor be installed and functional  
when the vehicle is operated on public lands.  
Operation of off-road vehicles on public lands in the U.S.A. is  
regulated by 43 CFR 8343.1(c). Violations are subject to monetary  
penalties. Federal regulations can be viewed online at  
www.gpoaccess.gov/ecfr/.  
Crankcase Emission Control System  
This engine is equipped with a closed crankcase system. Blow-by  
gases are forced back to the combustion chamber by the intake system.  
All exhaust gases exit through the exhaust system.  
Exhaust Emission Control System  
The emissions from the exhaust of this vehicle are controlled by engine  
design, including factory-set fuel delivery and ignition. The engine  
and related components must be maintained at Polaris specifications to  
achieve optimal performance.  
Engine idle speed is the only adjustment Polaris recommends that the  
operator perform. Any other adjustments should be performed by an  
authorized Polaris dealer.  
The emissions label is located on the left front portion of the frame or  
under the seat.  
Electromagnetic Interference  
This spark ignition system complies with Canadian ICES-002.  
This vehicle complies with the EMC requirements of European  
directives 97/24/EC and 89/336/EEC.  
59  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Periodic Maintenance Chart  
Careful periodic maintenance will help keep your vehicle in the safest,  
most reliable condition. Inspection, adjustment and lubrication of  
important components are explained in the periodic maintenance chart.  
Inspect, clean, lubricate, adjust and replace parts as necessary. When  
inspection reveals the need for replacement parts, use genuine Polaris  
parts available from your Polaris dealer.  
Record maintenance and service in the Maintenance Log beginning on  
page 116.  
NOTE: Service and adjustments are important for proper vehicle  
operation. If you’re not familiar with safe service and  
adjustment procedures, have a qualified dealer perform  
these operations.  
Maintenance intervals in the following chart are based upon average  
riding conditions and an average vehicle speed of approximately 10  
miles per hour. Vehicles subjected to severe use must be inspected and  
serviced more frequently.  
Severe Use Definition  
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.  
60  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Periodic Maintenance Chart  
Maintenance Chart Key  
"
Perform these procedures more frequently for vehicles subjected to  
severe use.  
E
Emission-related service (Failure to conduct this maintenance will  
not void the emissions warranty but may affect emissions.)  
Have an authorized Polaris dealer perform these services.  
J
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.  
Perform all services at whichever maintenance interval is reached first.  
Item  
Maintenance Interval  
(whichever comes first)  
Remarks  
Hours Calendar  
Miles  
(Km)  
Steering  
--  
--  
--  
--  
--  
--  
--  
--  
--  
--  
--  
Pre-Ride  
Pre-Ride  
Pre-Ride  
Pre-Ride  
Pre-Ride  
Pre-Ride  
Pre-Ride  
Pre-Ride  
Pre-Ride  
Pre-Ride  
Daily  
--  
--  
--  
--  
--  
--  
--  
--  
--  
--  
--  
Make adjustments as need-  
ed. See Pre-Ride Checklist  
on page 42.  
J
"
"
Front suspension  
Rear suspension  
Tires  
Brake fluid level  
Brake lever travel  
Brake system  
"
"
Wheels/fasteners  
Frame fasteners  
Engine oil level  
Air filter, pre-filter  
"
Inspect; clean often; replace  
as needed  
"
E
"
Air box sediment  
tube  
--  
--  
--  
--  
--  
Daily  
Daily  
--  
--  
--  
--  
--  
Drain deposits when visible  
Coolant  
(if applicable)  
Check level daily, change  
coolant every 2 years  
Headlamp/tail  
lamp  
Daily  
Check operation; apply  
dielectric grease if replacing  
Air filter,  
main element  
Weekly  
Weekly  
Inspect; replace as needed  
"
E
Recoil housing  
Drain water as needed,  
check often if operating in  
wet conditions  
61  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Periodic Maintenance Chart  
Item  
Maintenance Interval  
(whichever comes first)  
Remarks  
Hours Calendar  
Miles  
(Km)  
Brake pad wear  
10 H  
Monthly  
100 (160)  
Inspect periodically  
"
J
Battery  
20 H  
25 H  
25 H  
Monthly  
Monthly  
Monthly  
200 (320)  
250 (400)  
250 (400)  
Check terminals; clean; test  
Inspect level; change yearly  
Inspect; clean if needed  
Transmission oil  
"
Engine breather  
filter (if equipped)  
"
E
"
General  
50 H  
50 H  
50 H  
50 H  
50 H  
3 M  
6 M  
6 M  
6 M  
6 M  
500 (800)  
500 (800)  
500 (800)  
500 (800)  
500 (800)  
Lubricate all fittings, pivots,  
cables, etc.  
lubrication  
Carburetor float  
bowl  
Drain bowl periodically and  
prior to storage  
Throttle Cable/  
ETC Switch  
Inspect; adjust; lubricate;  
replace if necessary  
J
E
J
Choke cable  
Inspect; adjust; lubricate;  
replace if necessary  
E
E
Carburetor air  
intake ducts/  
flange  
Inspect ducts for proper  
sealing/air leaks  
Drive belt  
50 H  
50 H  
6 M  
6 M  
500 (800)  
Inspect; adjust; replace as  
needed  
Cooling system  
(if applicable)  
1000 (1600) Inspect coolant strength  
seasonally; pressure test  
system yearly  
Engine oil change 100 H  
6 M  
1000 (1600) Perform a break-in oil  
change at one month  
"
Oil filter change  
100 H  
6 M  
12 M  
12 M  
1000 (1600) Replace with oil change  
1000 (1600) Inspect routing, condition  
1000 (1600) Inspect; adjust  
"
"
Oil tank vent hose 100 H  
Valve clearance  
Fuel system/filter  
100 H  
100 H  
J
E
J
12 M  
1000 (1600) Check for leaks at tank cap,  
lines, fuel valve, filter, pump,  
carburetor; replace lines  
E
every two years  
Radiator  
(if applicable)  
100 H  
12 M  
1000 (1600) Inspect; clean external  
surfaces  
"
62  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Periodic Maintenance Chart  
Item  
Maintenance Interval  
(whichever comes first)  
Remarks  
Hours Calendar  
Miles  
(Km)  
Cooling hoses  
(if applicable)  
100 H  
12 M  
1000 (1600) Inspect for leaks  
"
"
Engine mounts  
100 H  
100 H  
12 M  
12 M  
1000 (1600) Inspect  
1000 (1600) Inspect  
Exhaust muffler/  
pipe  
Spark plug  
Ignition Timing  
Wiring  
100 H  
100 H  
100 H  
12 M  
12 M  
12 M  
1000 (1600) Inspect; replace as needed  
1000 (1600) Inspect  
J
E
J
E
"
1000 (1600) Inspect for wear, routing,  
security; apply dielectric  
grease to connectors  
subjected to water, mud, etc.  
Clutches (drive  
and driven)  
100 H  
100 H  
12 M  
12 M  
1000 (1600) Inspect; clean; replace worn  
parts  
J
J
J
Front wheel  
bearings  
1000 (1600) Inspect; replace as needed  
Brake fluid  
200 H  
300 H  
24 M  
36 M  
2000 (3200) Change every two years  
3000 (4800) Clean out  
Spark arrestor  
Idle speed  
--  
Adjust as needed  
Toe adjustment  
--  
Inspect periodically; adjust  
when parts are replaced  
J
Headlight aim  
--  
Adjust as needed  
"
Perform these procedures more often for vehicles subjected to severe use.  
Emission-Related Service  
Have an authorized Polaris dealer perform these services.  
E
J
63  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Lubrication Recommendations  
Check and lubricate all components at the intervals outlined in the  
Periodic Maintenance Chart beginning on page 60. Items not listed in  
the chart should be lubricated at the General Lubrication interval.  
NOTE: The a-arms and lower control arms are lubricated at the  
factory, and no additional lubrication will be needed.  
However, if these components are subjected to severe use,  
grease zerks have been provided for additional lubrication at  
the user’s discretion.  
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  
F
Use Polaris Premium U-Joint Lube every 500 miles, before long  
periods of storage, or after pressure washing or submerging  
When suspension action becomes stiff, or after washing  
Item  
Engine Oil  
Lube  
Method  
PS-4 PLUS Performance Add to proper level on dipstick.  
Synthetic 2W-50  
Brake Fluid  
DOT 4 fluid only  
Maintain level between fill lines.  
See page 35.  
Drive chain(s)  
(1) Transmission  
O-ring chain lube or SAE Lubricate.  
80/90  
AGL Synthetic  
Gearcase Lube  
Maintain as recommended on  
page 68.  
(2) Swing Arm  
Bushings  
Locate fittings on swing arm and  
grease with grease gun.  
"LGrease  
(3) Tie Rod Ends  
Lift boot, clean away dirt and  
grease, apply fresh grease by  
hand and reassemble.  
"LGrease  
(4) Axle Housing  
Locate fittings on swing arm and  
grease with grease gun.  
"L Grease  
64  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Lubrication Recommendations  
(2)  
(4)  
(1)  
(3)  
65  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Engine Oil  
Always check and change the engine oil at the intervals outlined in the  
Periodic Maintenance Chart beginning on page 60. Always change the  
oil filter whenever changing oil.  
Oil Recommendations  
Polaris recommends the use of Polaris PS-4 PLUS Performance  
Synthetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may  
need to be changed more frequently if Polaris oil is not used. Always  
use 2W-50 oil. Follow the manufacturer’s recommendations for  
ambient temperature operation.  
See page 107 for the part numbers of Polaris products.  
CAUTION  
Mixing brands or using a non-recommended oil may cause  
serious engine damage. Always use the recommended oil.  
Never substitute or mix oil brands.  
Oil Check  
The oil fill is located on the left side of the vehicle (1).  
1. Position the machine on a level surface.  
2. Start the engine and let it idle for 20-30 seconds. Stop the engine.  
3. Remove the dipstick and wipe it dry with a clean cloth.  
4. Screw the dipstick completely in.  
5. Remove the dipstick and read the oil level. Maintain the oil level in  
the safe operating range (2). Do not overfill.  
1
2
66  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Engine Oil  
Oil and Filter Change  
1. Position the vehicle on a level surface.  
2. Clean the area around the drain plug.  
3. Run the engine for two to three minutes until warm. Stop the  
engine.  
CAUTION  
Contact with hot oil may result in serious burns. Do not allow hot  
oil to come into contact with skin.  
4. Place a drain pan beneath the engine crankcase and remove the  
drain plug.  
5. Allow the oil to drain completely.  
6. Install a new sealing washer on the drain plug.  
NOTE: The sealing surfaces on the drain plug and crankcase should  
be clean and free of burrs, nicks or scratches.  
7. Reinstall the drain plug and torque to 14 ft. lbs. (19 Nm).  
8. Place shop towels beneath the oil filter. Using an oil filter wrench,  
turn the filter counterclockwise to remove.  
9. Using a clean, dry cloth, clean the filter sealing surface on the  
crankcase.  
10. Lubricate the gasket on the new filter with a film of engine oil.  
Check to make sure the gasket is in good condition.  
11. Install the new filter and turn by hand until the filter gasket  
contacts the sealing surface, then turn and additional 1/2 turn.  
12. Remove the dipstick and fill the sump with 1.7 quarts (1.6 l) of the  
recommended oil.  
13. Place the gear selector in neutral and set the parking brake.  
14. Start the engine and let it idle for one to two minutes. Stop the  
engine and inspect for leaks.  
15. Recheck the oil level and add oil as necessary to bring the level to  
the upper mark on the dipstick.  
16. Dispose of used filter and oil properly.  
67  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Transmission Oil  
Always check and change the transmission oil at the intervals outlined  
in the Periodic Maintenance Chart beginning on page 60. Maintain the  
oil level at the bottom of the fill hole threads. We recommend the use  
of Premium AGL Synthetic Gearcase Lubricant. See page 107 for the  
part numbers of Polaris products.  
Oil Check  
The transmission dipstick (1) is  
located on the right side of the  
machine near the recoil handle.  
1
NOTE: We recommend the use  
of Polaris Premium AGL  
Synthetic Gearcase Lube.  
See page 107 for the part  
numbers of Polaris  
products.  
1. Position the ATV on a level  
surface. Remove the dipstick  
and wipe it clean.  
2. Reinstall the dipstick completely, then remove it and check the  
level. Add the recommended lubricant to bring the level into the  
safe operating range. See Specifications beginning on page 104 for  
capacity.  
68  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Transmission Oil  
Oil Change  
1. Place a drain pan beneath the  
transmission oil drain plug  
area.  
A
B
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.  
C
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.  
69  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Toe Alignment  
WARNING  
Severe injury or death can result from improper toe alignment and  
adjustment. Do not attempt to adjust tie rod alignment. All tie rod  
adjustments should be performed by an authorized Polaris dealer.  
Use the following procedure to check the toe alignment of the vehicle.  
The recommended toe alignment is 1/8to 1/4toe out.  
1. Position the vehicle on a level  
surface.  
2. Set the handlebars in a  
straight-ahead position  
B
and secure them in this  
position.  
3. Place a chalk mark on the  
center line of the front  
tires approximately 10″  
(25.4 cm) from the floor,  
or as close to the hub/axle  
center line as possible.  
Make sure both marks are  
the same distance from  
the floor.  
A
4. Measure the distance between the marks and record the  
measurement (A).  
5. Move the vehicle until the chalk marks are at the rear of the tires,  
even with the hub/axle centerline.  
6. Measure the distance between the marks and record the  
measurement (B).  
7. Subtract measurement B from measurement A. The difference is  
the vehicle toe-out alignment.  
NOTE: If you discover improper alignment, see your Polaris dealer  
for service.  
70  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Brakes  
The front and rear brakes are hydraulic disc brakes, activated by  
moving the single brake lever toward the handlebar. These brakes are  
self-adjusting.  
The following checks are recommended to keep the brake system in  
good operating condition. Check more often if brakes are used heavily  
under normal operation, such as in hilly country or in muddy terrain.  
WARNING  
Never store or use a partial bottle of brake fluid. Brake fluid is  
hygroscopic, meaning it rapidly absorbs moisture from the air.  
The moisture causes the boiling temperature of the brake fluid to  
drop, which can lead to early brake fade and the possibility of  
accident or severe injury. After opening a bottle of brake fluid,  
always discard any unused portion.  
1. Always maintain brake fluid at an adequate level (see page 35).  
WARNING  
An over-full master cylinder may cause brake drag or brake  
lock-up, which could result in serious injury or death. Maintain  
brake fluid at the recommended level. Do not overfill.  
NOTE: Under normal operation, the diaphragm extends into the  
reservoir as fluid level drops. If the fluid level is low and the  
diaphragm is not extended, a leak is likely and the diaphragm  
should be replaced. Always fill the reservoir as needed  
whenever the cover is loosened or removed to ensure proper  
diaphragm operation. Use Polaris DOT 4 brake fluid. Do not  
overfill.  
71  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Brakes  
1. Check the brake system for fluid leaks.  
2. Check the brakes for excessive travel or  
spongy feel.  
3. Check the friction pads for wear,  
damage and looseness.  
4. Check the security and surface  
condition of the disc.  
NOTE: Pads should be changed when  
worn to 3/64(.1 cm).  
3/64(.1 cm)  
Auxiliary Brake  
The auxiliary brake system is intended to be used as a backup for the  
main brake system. Should the main system fail, the rear brake can be  
activated by depressing the foot pedal on the inside of the right  
footrest. The hydraulic auxiliary brake system requires no adjustment.  
NOTE: Since this is a rear brake only, it will not be as effective as  
the all-wheel single lever system.  
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  
1
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.  
72  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Throttle Cable Freeplay  
Throttle cable freeplay is adjusted at the handlebar.  
1. Locate the throttle cable  
adjuster on the  
handlebar.  
2. Squeeze the end of the  
rubber boot (1) and slide  
it far enough to expose  
the end of the inline  
cable adjuster (2).  
3. Loosen the locknut (3).  
4. Rotate the boot to turn  
the adjuster until 1/16″  
to 1/8(2-3 mm)  
freeplay is achieved at  
the thumb lever.  
1
NOTE: While adjusting  
freeplay, be sure  
to flip the throttle  
lever back and  
forth.  
3
2
5. Tighten the locknut.  
6. Squeeze the end of the  
rubber boot and slide it  
over the cable adjuster to  
its original position.  
73  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Handlebars  
WARNING  
Improper adjustment of the handlebars or incorrect torquing of  
the adjuster block tightening bolts can cause limited steering or  
loosening of the handlebars, resulting in loss of control and  
possible serious personal injury or death. Follow the adjustment  
procedures exactly, or see your Polaris dealer for service.  
1
The handlebars can be adjusted for  
rider preference.  
1. Remove the handlebar cover to  
access the handlebar bolts (1).  
2. Loosen the four bolts.  
3. Adjust the handlebar to the  
desired height. Be sure the  
handlebars do not contact the  
gas tank or any other part of the  
machine when turned fully to  
the left or right.  
4. Torque the two front bolts to 10-12 ft. lbs. (14-17 Nm), then  
torque the two rear bolts. A gap of up to 1/8” will remain at the  
rear bolts.  
74  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Carburetor  
IMPORTANT: Your Polaris ATV is calibrated at the factory for  
optimal performance at altitudes ranging from zero to 6,000 feet (1800  
m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above  
6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and  
the engine loses approximately 3% of its power for each 1000-foot  
(304.8 m) increase in elevation. Although this power cannot be  
regained, adjustments to the carburetor and drive system can be made  
to allow more efficient operation. Optional jets, available from your  
Polaris dealer, are required for operation above 6,000 feet and  
temperatures below +40 degrees F. (4 degrees C.)  
NOTE: Continuous operation of the engine without proper jetting  
when required can cause poor performance, overheating and  
engine or PVT damage. See your Polaris dealer for more  
information about jetting the ATV for conditions in your area.  
If the engine idle speed is not satisfactory, and all other conditions are  
favorable, the carburetor can be adjusted.  
1. Warm up the engine by running the  
vehicle for approximately five minutes.  
2. Place the transmission in gear and engage  
the parking brake.  
3. Adjust the carburetor idle screw (1) either  
in or out until the desired idle RPM is  
reached. Refer to the specifications  
section beginning on page 104 for the  
proper setting.  
NOTE: Turn the screw in (clockwise) to raise  
1
RPM. Turn the screw out  
(counterclockwise) to lower RPM.  
75  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Wheels  
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.  
76  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Wheels  
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 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 nuts to specification.  
Wheel Nut Torque Specifications  
Check the wheel nut torques occasionally and when they’ve been  
loosened for maintenance.  
Item  
Specification  
27 ft. lbs. (37 Nm)  
50 ft. lbs. (68 Nm)  
Front Wheel Nuts  
Rear Wheel Nuts  
Front  
Rear  
ft. lbs.  
Nm)  
27 ft. lbs.  
(37 Nm)  
77  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Wheels  
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.  
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.  
78  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Drive Chain  
Polaris ATV drive chains are equipped with o-ring-sealed, permanently  
greased pins and rollers. However, the outer surfaces of the roller must  
be lubricated.  
Always inspect the drive chain prior to operating the vehicle. Check for  
damaged or missing o-rings or damaged rollers. Also check for correct  
slack adjustment. Maintain the stone guard to rear sprocket clearance  
at 1/8(.3 cm).  
Regularly lubricate the drive chain with Polaris Chain Lube, an SAE  
80-90 lube or an approved o-ring chain spray lube. See page 107 for the  
part numbers of Polaris products.  
CAUTION  
Washing the drive chain with a high pressure washer or gasoline  
can cause damage to the o-rings, causing premature wear and  
drive chain failure. Do not use a high pressure washer or gasoline  
to clean the drive chain.  
79  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Drive Chain  
Rear Drive Chain Slack  
CAUTION  
Adjusting or operating the ATV with improper rear drive chain  
slack can result in severe damage to the transmission and drive  
components. Always make sure the slack is within the stated  
specifications.  
Check the amount of chain slack in three different locations by moving  
the vehicle slightly forward to gain slack at the top side of the rear  
chain. Measure the chain slack at the tightest of the three positions. At  
this point the chain should have 3/16-3/8(.48 cm - .95 cm)  
deflection. Use the following procedure if adjustment is required.  
1
3/16-3/8(.48 cm - .95 cm)  
2
1. Remove the chain guard.  
2. Loosen the chain guide.  
3. Loosen the two eccentric  
locking bolts (1).  
4. Loosen the caliper mounting  
bolt located on the left side  
of the swing arm.  
1
5. Insert a pin punch (2) through the sprocket hub and into the  
eccentric housing.  
80  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Drive Chain  
Rear Drive Chain Slack  
6. Roll the ATV forward or backward  
to adjust the chain slack to the  
proper tension. See the illustration  
for proper splice link clip opening  
position (1).  
7. Tighten the eccentric locking bolts  
to 30 ft. lbs. (41 Nm) for machines  
without the hitch and 45 ft. lbs. (61  
Nm) for machines with a hitch.  
1
8. Tighten the caliper mount bolt to 15 ft. lbs. (20 Nm).  
9. Remove the pin punch.  
10. Roll the ATV forward, checking chain tension in several places  
around the chain.  
NOTE: The chain is adjusted correctly when the tightest portion of  
the chain has approximately 3/8” (10mm) deflection.  
11. Position the chain guide to allow 1/8” (3mm) clearance and tighten  
the retaining bolt to 5 ft. lbs. (7 Nm).  
12. Reinstall the chain guard.  
81  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Lights  
When servicing a halogen lamp, don’t touch the lamp with bare  
fingers. Oil from your skin leaves a residue, causing a hot spot that  
will shorten the life of the lamp.  
WARNING  
Poor lighting while driving can result in severe injury or death.  
Headlight and taillight lenses become dirty during normal  
operation. Wash the headlights frequently to maintain lighting  
quality.  
Hot components can cause serious burns to skin. 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.  
82  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
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).  
3. Apply dielectric grease to the  
socket and install the new  
lamp.  
1
4. Test the taillight/brakelight for  
proper operation.  
5. Reinstall the gasket and lens cover.  
Indicator Lamp Replacement  
1. Remove the instrument panel, if necessary, to access the back of  
the indicator panel.  
2. Using a small, straight-blade screwdriver, turn the base of the bulb  
1/4 turn counterclockwise.  
3. Using a needle-nose plier or similar tool, pull the lamp out of the  
indicator panel housing.  
4. Insert the new bulb and seat it by turning it 1/4 turn clockwise.  
5. Reinstall the instrument panel if removed.  
83  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Air Filter  
1. Remove the seat, release the  
clips, and remove the air box  
cover.  
2. Loosen the clamp and remove the  
filter.  
2
3. If equipped, remove the fabric  
type pre-filter (1) from the main  
filter (2). Wash the pre-filter in  
soapy water, then rinse and let  
dry. Reinstall the pre-filter over  
the main filter.  
1
4. Replace the main filter with a  
new filter if needed.  
5. Reinstall the filter into the air box  
and tighten the clamp. Do not  
over tighten the clamp, as filter  
damage could occur.  
84  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Spark Plugs  
Spark Plug Recommendations  
CAUTION  
Using non-recommended spark plugs can result in serious engine  
damage. Always use Polaris-recommended spark plugs. Refer  
to the specifications section beginning on page 104.  
Refer to the specifications section beginning on page 104 for the  
recommended spark plug type and gap for your vehicle. Torque spark  
plugs to specification.  
Plug Condition  
New Spark Plug  
Torque Specification  
9-11 ft. lbs. (12-15 Nm)  
17-20 ft. lbs. (23-27 Nm)  
Previously Installed Spark Plug  
Spark Plug Inspection  
Spark plug condition is indicative of engine operation. Check the spark  
plug firing end condition after the engine has been warmed up and the  
vehicle has been driven at higher speeds. Immediately check the spark  
plug for correct color. See page 86.  
WARNING  
A hot exhaust system and engine can cause serious burns. Wear  
protective gloves when removing a spark plug for inspection.  
1. Remove the spark plug cap.  
2. Using the special wrench provided in the tool pouch, rotate the  
spark plug counterclockwise to remove it.  
3. Reverse the procedure for spark plug installation. Torque to  
specification.  
85  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Spark Plugs  
Spark Plug Inspection  
Normal Plug  
The normal insulator tip is gray, tan or light brown. There will be few  
combustion deposits. The electrodes are not burned or eroded. This  
indicates the proper type and heat range for the engine and the service.  
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.  
Wet Fouled Plug  
The wet fouled insulator tip is black. A damp oil film covers the firing  
end. There may be a carbon layer over the entire nose. Generally, the  
electrodes are not worn. General causes of fouling are excessive oil,  
use of non-recommended injection oil, improper use of the choke, or  
incorrect carburetion adjustments.  
Recoil Housing  
To prevent possible engine damage,  
1
always drain the recoil housing (1)  
after operating the ATV in very wet  
conditions. This should also be  
done before storing the ATV.  
Water will enter the recoil housing  
if the starter handle is disengaged  
from the rope guide when under  
water.  
The drain screw is located at the  
bottom of the recoil housing. Use a  
wrench to remove the screw. Be sure to reinstall the screw after  
draining the housing.  
NOTE: Do not open the crankcase drain unless the engine has  
ingested water. On 4-cycle engines, some engine oil will be  
lost if the crankcase drain is opened.  
86  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Vehicle Immersion  
CAUTION  
If your vehicle becomes immersed, major engine damage can  
result if the machine is not thoroughly inspected. Take the  
vehicle to your dealer before starting the engine.  
If it’s impossible to take your ATV to a dealer before starting it, follow  
the steps outlined below.  
1. Move the ATV to dry land or at the  
very least, to water below the  
footrests.  
2. Check the airbox for any water. Drain  
and dry it if water is present.  
3. Turn the fuel valve off.  
4. Remove the spark plug.  
5. Turn the engine over several times  
using the electric start.  
1
6. Loosen the carburetor drain screw (1).  
7. Dry the spark plug and reinstall, or replace it with a new plug.  
8. Tighten the carburetor drain screw.  
9. Turn the fuel valve on.  
10. Attempt to start the engine. If necessary, repeat the drying  
procedure.  
11. Take the ATV to your dealer for service as soon as possible,  
whether you succeed in starting it or not.  
NOTE: If water has been ingested into the PVT, follow the procedure  
on page 89 for drying out the PVT.  
87  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
PVT System  
The basic operation of the Polaris PVT system is dependent on engine  
speed and vehicle torque requirements. As engine speed increases, the  
force exerted on the movable drive sheave by the flyweights also  
increases. This, in turn, increases the amount of “pinch” applied to the  
drive belt. Similarly, if the engine speed decreases, the amount of  
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.  
88  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
PVT System  
WARNING  
Failure to comply with the instructions in this warning can result in  
severe injury or death.  
Do not modify any component of the PVT system. Doing so may  
reduce its strength so that a failure may occur at a high speed.  
The PVT system has been precision balanced. Any modification  
will cause the system to be out of balance, creating vibration and  
additional loads on components.  
The PVT system rotates at high speeds, creating large amounts  
of force on clutch components. Extensive engineering and  
testing has been conducted to ensure the safety of this product.  
However, as the owner, you have the following responsibilities to  
make sure this system remains safe:  
Always follow all recommended maintenance procedures. See  
your dealer as outlined in the owner’s manual.  
This PVT system is intended for use on Polaris products only. Do  
not install it in any other product.  
Always make sure the PVT housing is securely in place during  
operation.  
PVT Drying  
There may be some instances when water is accidently ingested into  
the PVT system. Use the following instructions to dry it out before  
operating:  
1. Remove the drain plug and allow the water to drain. Reinstall the  
drain plug.  
2. Start the engine and shift the transmission into neutral. Apply  
varying throttle for 10-15 seconds to expel the moisture and air-dry  
the belt and clutches. Do not hold the throttle wide open for more  
than 10 seconds.  
3. Allow the engine RPM to settle to idle speed, then shift the  
transmission to the lowest available range.  
4. Test for belt slippage. If the belt slips, repeat the process.  
5. Take the vehicle to your dealer for service as soon as possible.  
89  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
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  
2
momentarily revving the engine  
1
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.  
90  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Battery  
Your ATV may have either a sealed battery, which requires little  
maintenance, or a conventional battery. A sealed battery can be  
identified by its flat covers on the top of the battery. A conventional  
battery has six filler caps on the top of the battery.  
Always keep battery terminals and connections free of corrosion. If  
cleaning is necessary, remove corrosion with a stiff wire brush. Wash  
with a solution of one tablespoon baking soda and one cup water.  
Rinse well with tap water and dry off with clean shop towels. Coat the  
terminals with dielectric grease or petroleum jelly. Be careful not to  
allow cleaning solution or tap water into a conventional battery.  
Conventional Battery  
WARNING  
Battery electrolyte is poisonous. It contains sulfuric acid. Serious  
burns can result from contact with skin, eyes or clothing.  
Antidote:  
External: Flush with water.  
Internal: Drink large quantities of water or milk. Follow with milk  
of magnesia, beaten egg, or vegetable oil. Call physician  
immediately.  
Eyes: Flush with water for 15 minutes and get prompt medical  
attention.  
Batteries produce explosive gases. Keep sparks, flame,  
cigarettes, etc. away. Ventilate when charging or using in an  
enclosed space. Always shield eyes when working near  
batteries. KEEP OUT OF REACH OF CHILDREN.  
91  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Battery  
WARNING  
Improperly connecting or disconnecting battery cables can result  
in an explosion and cause serious injury or death. When  
removing the battery, always disconnect the negative (black)  
cable first. When reinstalling the battery, always connect the  
negative (black) cable last.  
Battery Removal  
1. Disconnect the hold-down strap holding the battery in position, and  
remove battery cover.  
2. On conventional batteries, remove the battery vent tube.  
3. Disconnect the black (negative) battery cable first.  
4. Disconnect the red (positive) battery cable next.  
5. Lift the battery out of the ATV. Be careful not to tip a conventional  
battery sideways, which could spill electrolyte.  
CAUTION  
If electrolyte spills, immediately wash it off with a solution of one  
tablespoon baking soda and one cup water to prevent damage to  
the vehicle.  
92  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Battery  
Battery Installation  
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 pages 95-97  
before installing the battery.  
1. Ensure that the battery is fully charged.  
2. Place the battery in the battery holder.  
3. With conventional batteries, install the battery vent tube (sealed  
batteries do not have a vent tube).  
NOTE: The vent tube must be free of obstructions and securely  
installed. Route the tube away from the frame and vehicle  
body to prevent contact with electrolyte.  
WARNING  
Battery gases could accumulate in an improperly installed vent  
tube and cause an explosion, resulting in serious injury or death.  
Always ensure that the vent tube is free of obstructions and is  
securely installed as recommended.  
4. On conventional batteries, coat the terminals with dielectric grease  
or petroleum jelly.  
5. Connect and tighten the red (positive) cable first.  
6. Connect and tighten the black (negative) cable last.  
7. Install the battery cover.  
8. Secure the battery hold-down strap.  
9. Verify that cables are properly routed.  
NOTE: Cables should be safely tucked away at the front and rear of  
the battery.  
93  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Battery  
Battery Storage  
Whenever the vehicle is not used for a period of three months or more,  
remove the battery from the vehicle, ensure that it’s fully charged, and  
store it out of the sun in a cool, dry place. Check battery voltage each  
month during storage and recharge as needed to maintain a full charge.  
NOTE: Power plug leads may need to be bent down so that the  
battery cover can be installed.  
NOTE: Battery charge can be maintained by using a Polaris Battery  
Tender charger or by charging about once a month to make  
up for normal self-discharge. Battery Tender can be left  
connected during the storage period, and will automatically  
charge the battery if the voltage drops below a  
pre-determined point. See page 107 for the part numbers of  
Polaris products.  
94  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Battery  
Battery Fluid (Conventional Battery)  
A poorly maintained battery will  
deteriorate rapidly. Check the battery  
fluid level often. Maintain the fluid  
level between the upper and lower level  
marks (1).  
1
Add only distilled water. Tap water  
contains minerals that are harmful to a  
battery.  
Battery Charging (Conventional Battery)  
1. Remove the battery from the vehicle to prevent damage from  
leaking or spilled electrolyte during charging. See page 92.  
2. Charge the battery with a charging output no larger than 1/10 of the  
battery’s amp/hr rating. Charge as needed to raise the specific  
gravity to 1.270 or greater.  
3. Reinstall the battery. See page 93. Make sure the positive terminal  
is toward the front of the vehicle.  
95  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Battery  
Battery Charging (Sealed Battery)  
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. Never pry the sealing strip off or add  
any other fluid to this battery.  
The single most important thing about maintaining a sealed battery is  
to keep it fully charged. Since the battery is sealed and the sealing strip  
cannot be removed, you must use a voltmeter or multimeter to measure  
DC voltage.  
WARNING  
An overheated battery could explode, causing severe injury or  
death. Always watch charging times carefully. Stop charging if the  
battery becomes very warm to the touch. Allow it to cool before  
resuming charging.  
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.  
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.  
96  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Battery  
Battery Charging (Sealed Battery)  
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  
Needs Charge  
5-11 hours  
At least 13 hours,  
verify state of charge  
0%-25%  
11.5 volts or less  
Needs Charge  
At least 20 hours  
97  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Cleaning and Storage  
See page 107 for the part numbers of Polaris products.  
Washing the Vehicle  
Keeping your ATV clean will not only improve its appearance but it  
can also extend the life of various components.  
CAUTION  
High water pressure may damage ATV components. Polaris  
recommends washing the vehicle by hand or with a garden hose,  
using mild soap.  
Certain products, including insect repellants and chemicals, will  
damage plastic surfaces. Do not allow these types of products to  
come into contact with the vehicle.  
The best and safest way to clean your Polaris vehicle is with a garden  
hose and a pail of mild soap and water.  
1. Use a professional--type washing cloth, cleaning the upper body  
first and the lower parts last.  
2. Rinse with clean water frequently.  
3. Dry surfaces with a chamois to prevent water spots.  
Washing Tips  
S Avoid the use of harsh cleaners, which can scratch the finish.  
S Do not use a power washer to clean the vehicle.  
S Do not use medium to heavy duty compounds on the finish.  
S Always use clean cloths and pads for cleaning and polishing. Old or  
reused cloths and pads may contain dirt particles that will scratch the  
finish.  
98  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Cleaning and Storage  
Washing the Vehicle  
If a high pressure water system is used for cleaning (not  
recommended), exercise extreme caution. The water may damage  
components and could remove paint and decals. Avoid directing the  
water stream at the following items:  
S Wheel bearings  
S Radiator (if equipped)  
S Transmission seals  
S Brakes  
S Cab and body panels  
S Labels and decals  
S Electrical components and wiring  
NOTE: If warning and safety labels are damaged, contact your  
Polaris dealer for free replacement.  
Grease all zerk fittings immediately after washing. Allow the engine to  
run for a while to evaporate any water that may have entered the engine  
or exhaust system.  
Polishing the Vehicle  
Polaris recommends the use of common household aerosol furniture  
polish for polishing the finish on your Polaris vehicle. Follow the  
instructions on the container.  
Polishing Tips  
S Avoid the use of automotive products, some of which can scratch the  
finish of your vehicle.  
S Always use clean cloths and pads for cleaning and polishing. Old or  
reused cloths and pads may contain dirt particles that will scratch the  
finish.  
99  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
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.  
NOTE: Chrome wheels exposed to road salt (or salt in the air in  
coastal areas) are more susceptible to corrosion if not  
properly cleaned. Clean chrome wheels more often if they’re  
exposed to salt or other corrosive elements.  
1. Wash chrome wheels frequently. Use a mild detergent. Never use  
abrasive cleaners on plated or painted surfaces.  
2. Rinse well with clear water. Soap, detergents, salt, dirt, mud and  
other elements can cause corrosion.  
3. Polish the clean chrome wheels periodically. Use an automotive  
grade chrome polish.  
4. Routinely and liberally apply a weather resistant wax to each  
polished chrome wheel. Choose a product suitable for chrome  
finishes. Read and follow the product labels and instructions.  
Removing Corrosion  
If light rust is found on the chrome finish, use steel wool (#0000--OTT  
grade) to remove it. Gently rub the affected areas with the steel wool  
until the corrosion has been removed. Clean and polish the wheel as  
outlined above.  
100  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Cleaning and Storage  
Storage Tips  
See page 107 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.  
Clean the Exterior  
Make any necessary repairs and clean the vehicle as recommended. See  
page 98.  
Fuel Stabilizer  
1. Fill the fuel tank.  
2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel  
Stabilizer. Follow the instructions on the container for the  
recommended amount.  
NOTE: Carbon Clean removes water from fuel systems, stabilizes  
fuel and removes carbon deposits from pistons, rings, valves  
and exhaust systems.  
3. Allow the engine to run for 15--20 minutes to allow the stabilizer to  
disperse through the fuel in the tank and carburetor.  
4. Turn the fuel valve off.  
5. Drain the carburetor bowl.  
Oil and Filter  
Change the oil and filter. See page 67.  
Air Filter / Air Box  
1. Inspect and clean (or replace) the pre-cleaner and air filter.  
2. Clean the air box.  
3. Drain the sediment tube.  
Recoil Housing  
Drain the recoil housing. See page 86.  
101  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Cleaning and Storage  
Storage Tips  
Fluid Levels  
Inspect the fluid levels. Add or change fluids as recommended in the  
Periodic Maintenance Chart beginning on page 60.  
S Transmission fluid  
S Brake fluid (change every two years and any time the fluid looks  
dark or contaminated)  
Fog the Engine  
1. Support the front end of the machine so the engine is level or tilted  
slightly rearward.  
2. Remove the spark plug.  
3. Pour 2-3 tablespoons (29-44 ml) of engine oil into the hole.  
NOTE: Use a section of small hose and a small plastic squeeze bottle  
filled with the pre-measured amount of oil.  
4. Reinstall the spark plug. Torque to specification.  
5. Apply dielectric grease to the inside of the spark plug cap.  
Reinstall the cap.  
6. Turn the engine over several times using the recoil starter. Oil will  
be forced in and around the piston rings and ring lands, coating the  
cylinder with a protective film of fresh oil.  
7. Treat the fuel system with Polaris Carbon Clean. See page 101.  
8. If Polaris fuel system additive is not used, the fuel tank, fuel lines,  
and carburetor should be completely drained of gasoline.  
9. To eliminate any fuel remaining in the carburetor, run the engine  
until it stops.  
102  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Cleaning and Storage  
Storage Tips  
Inspect and Lubricate  
Inspect all cables and lubricate all areas of the vehicle as recommended  
in the Periodic Maintenance Chart beginning on page 60.  
Battery Storage  
See pages 94-97 for storage and charging procedures.  
Storage Area/Covers  
Set the tire pressure and safely support the ATV with the tires slightly  
off the ground. Be sure the storage area is well ventilated. Cover the  
vehicle with a genuine Polaris cover.  
NOTE: Do not use plastic or coated materials. They do not allow  
enough ventilation to prevent condensation, and may promote  
corrosion and oxidation.  
Transporting the ATV  
Follow these procedures when  
transporting the vehicle.  
1. Turn off the engine and  
remove the key to prevent loss  
during transporting.  
2. Turn the fuel valve off.  
3. Be sure the fuel cap, oil cap  
and seat are installed correctly.  
4. Always tie the frame of the  
ATV to the transporting unit  
securely using suitable straps  
or rope.  
5. Always place the transmission  
in gear and lock the parking  
brake.  
103  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SPECIFICATIONS  
2008 Trail Blazer 330  
Capacities & Dimensions  
Body Style  
Gen III  
Dry Weight  
488 lbs. (221 kg)  
305 lbs. (138 kg)  
30 lbs. (14 kg)  
60 lbs. (27 kg)  
850 lbs.(386 kg)  
Maximum Weight Capacity  
Front Rack Capacity (Accessory)  
Rear Rack Capacity (Accessory)  
Hitch Towing Rating (Accessory)  
Unbraked Trailer Towing Capacity* 1263 lbs. (573 kg)  
Tongue Weight  
Fuel Capacity  
Transmission Oil Capacity  
Engine Oil Capacity  
85 lbs. (38.6 kg)  
3.25 gal. (12.3 l)  
11.3 oz. (33 ml)  
1.9 qts. (1.8 l) (including oil cooler)  
1.7 qts. (1.6 l) (at oil change)  
Turn Radius  
Ground Clearance  
Length  
Width  
Height  
83 in. (211 cm)  
5.5 in. (14 cm)  
75 in. (190.5 cm)  
46 in. (117 cm)  
46 in. (117 cm)  
48 in. (122 cm)  
Wheel Base  
Engine & Cooling  
Engine Model Number / Type  
Lubrication  
ES-32PFE-103 / 4 Cycle, Single Cylinder  
Wet Sump  
Bore x Stroke  
Displacement  
Compression Ratio  
Engine Cooling  
Alternator Output (watts)  
Carburetion  
78.5 x 68  
329cc  
9.2:1  
Air with fan assisted oil cooler  
200w @5000 rpm  
BST 34  
Main Jet  
122.5  
Pilot Jet  
42.5  
Needle Jet  
P-4 (829)  
Pilot Air Jet  
160  
Pilot Screw  
2.0 turns  
Jet Needle  
4HB48-3  
Ignition  
DC CDI  
Timing  
Spark Plug Type / Gap  
30° ± 2° @ 5000 RPM  
BKR6E / .036 in. (.9 mm)  
* Based on EU Directive 76/432/EC  
104  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SPECIFICATIONS  
2008 Trail Blazer 330  
Drive System  
Drive System Type  
Shift Type  
Automatic Polaris Variable Transmission (PVT)  
Side Lever (H-N-R)  
3.05:1  
Gear Reduction - Reverse  
Gear Reduction - Forward  
Final Drive (ratio)  
Drive Chain  
2.68:1  
11/40 78P  
520 O-Ring  
Front Tires / Pressure  
Rear Tires / Pressure  
23 x 7-10 / 4 psi (27.6 KPa)  
22 x 11-10 / 3 psi (20.7 KPa)  
Suspension and Brakes  
Front Suspension  
Rear Suspension  
MacPherson strut with 8.2 in. (21 cm) travel  
Progressive Rate Swing Arm with 10.5 in. (27  
cm) travel  
Shock Adjustment  
Front/Rear Brakes  
Auxiliary Foot Brake  
Parking Brake  
CAM  
Hydraulic disc  
Hydraulic disc  
Hydraulic lock, all wheel  
Features  
Headlight  
1 Single Beam, 55w  
8.26w  
Taillight  
Brake Light  
26.9w  
Battery  
12V 14 AH  
Accessory  
Accessory  
Standard  
DC Plug-In (Rear)  
DC Socket (Forward)  
Electric Start  
High Temp Indicator  
Windshield  
Standard  
Accessory  
Standard  
Neutral Indicator  
Reverse Indicator  
Speedometer  
Fuel Gauge  
Standard  
Accessory  
Standard  
Tool Kit  
Standard  
105  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SPECIFICATIONS  
2008 Trail Blazer 330  
Jetting Chart  
Altitude  
AMBIENT  
TEMPERATURE  
Below 40° F  
(Below 5° C)  
+40°F and above  
(+5°C and above)  
Meters  
(Feet)  
0-1800  
(0-6000)  
127.5  
122.5  
1800-3700  
(6000-12000)  
120  
115  
Clutching Chart  
Altitude  
Shift  
Weight  
Drive Clutch Driven Clutch  
Helix/Spring  
Setting  
Spring  
Spring  
Meters  
(Feet)  
0-1800  
(0-6000)  
10RH  
5630709  
Blue/Green  
7041157  
Black  
7041782  
45  
5131446  
2--2  
1800-3700  
(6000-12000)  
20-40  
5631356  
Blue/Green  
7041157  
Black  
7041782  
45  
5131446  
2--2  
106  
Download from Www.Somanuals.com. All Manuals Search And Download.  
POLARIS PRODUCTS  
Part No.  
Description  
Engine Lubricant  
2870791  
2876244  
2876245  
Fogging Oil (12 oz. Aerosol)  
PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt.)  
PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal.)  
Gearcase / Transmission Lubricants  
Premium AGL Synthetic Gearcase Lube (qt.)  
Premium AGL Synthetic Gearcase Lube (gal.)  
Premium ATV Angle Drive Fluid (8 oz.)  
Premium ATV Angle Drive Fluid (2.5 gal.)  
Pump for Gallon Jug  
2873602  
2873603  
2871653  
2872276  
2870465  
2871654  
2872277  
Premium Demand Drive Hub Fluid (8 oz.)  
Premium Demand Drive Hub Fluid (2.5 gal.)  
Grease / Specialized Lubricants  
Premium All Season Grease (3 oz. cartridge)  
Premium All Season Grease (14 oz. cartridge)  
Starter Drive Grease  
Premium U-Joint Lube (3 oz.)  
Premium U-Joint Lube (14 oz.)  
Grease Gun Kit  
Dielectric Grease (Nyogelt)  
Chain Lube (6.25 oz. aerosol)  
Chain Lube (16 oz. aerosol)  
2871322  
2871423  
2871460  
2871515  
2871551  
2871312  
2871329  
2872073  
2872348  
Additives / Miscellaneous  
Carbon Clean Plus (12 oz.)  
Fuel Stabilizer (16 oz.)  
DOT 4 Brake Fluid  
LOCTITE 565 Thread Sealant  
Polaris Battery Tendert Charger  
2871326  
2870652  
2872189  
2871956  
2859044  
107  
Download from Www.Somanuals.com. All Manuals Search And Download.  
TROUBLESHOOTING  
Contact your Polaris dealer for service if you’re unable to identify  
solutions using the following charts.  
Drive Belt and Cover Problems  
Possible Cause  
Solution  
Driving onto a pickup or Shift transmission to low range during loading of the ATV  
tall trailer in high range  
to prevent belt burning.  
Starting out going up a  
steep incline  
When starting out on an incline, use low range or dis-  
mount the ATV (after first applying the park brake) and  
perform the K-turn as described on page 54.  
Driving at low RPM or  
low ground speed (at  
Drive at a higher speed or use low range more frequently.  
The use of low range is highly recommended for cooler  
approximately 3-7 MPH) PVT operating temperatures and longer component life.  
Insufficient warm-up of  
Warm the engine at least 5 minutes. With the transmission  
ATVs exposed to low am- in neutral, advance the throttle to about 1/8 throttle in  
bient temperatures  
short bursts, 5 to 7 times. The belt will become more flex-  
ible and prevent belt burning.  
Slow/easy clutch engage- Use the throttle quickly and effectively.  
ment  
Towing/pushing at low  
RPM/low ground speed  
Use low range only.  
Utility use/plowing  
Use low range only.  
Stuck in mud or snow  
Shift the transmission to low range, and carefully use fast,  
aggressive throttle application to engage clutch.  
WARNING: Excessive throttle may cause loss of control  
and vehicle overturn.  
Climbing over large  
objects from a stopped  
position  
Shift the transmission to low range and carefully use fast,  
brief, aggressive throttle application to engage clutch.  
WARNING: Excessive throttle may cause loss of control  
and vehicle overturn.  
Belt slippage from water Shift the transmission to neutral. Using the throttle, vary  
or snow ingestion into the the engine RPM from idle to full throttle. Repeat several  
PVT system  
times as required. During this procedure, the throttle  
should not be held at the full position for more than 10  
seconds. Clutch seals should be inspected for damage if  
repeated leaking occurs.  
Clutch malfunction  
See your Polaris dealer.  
Poor engine performance Check for fouled plugs or foreign material in gas tank,  
fuel lines, or carburetor. See your dealer.  
Slippage from failure to  
warm up belt  
Always warm up the belt by operating below 30 mph for  
one mile (5 miles or more when temperature is below  
freezing).  
Wrong or missing belt  
Improper break-in  
Always use the recommended belt.  
Always break in a new belt and/or clutch by avoiding  
aggressive or high speed operation during the first two full  
tanks of fuel.  
108  
Download from Www.Somanuals.com. All Manuals Search And Download.  
TROUBLESHOOTING  
Engine Doesn’t Turn Over  
Possible Cause  
Solution  
Tripped circuit breaker  
Low battery voltage  
Reset the breaker  
Recharge battery to 12.8 VDC  
Check all connections and tighten  
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  
109  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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  
See your Polaris dealer  
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  
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  
110  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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  
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  
See your Polaris dealer  
See your Polaris dealer  
111  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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. 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.  
112  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
SPARK ARRESTOR  
Polaris warrants that the spark arrestor in this vehicle will meet the efficiency requirements  
of 43 CFR 8343.1(c) for at least 1000 hours whensubjected tonormal useand whenmainte-  
nance and installation are in accordance with Polaris recommendations.  
113  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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: 1-888-704-5290  
Canada: 1-204-925-7100  
114  
Download from Www.Somanuals.com. All Manuals Search And Download.  
WARRANTY  
U.S.A. EPA Emissions Limited Warranty  
This All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited  
warranty is in addition to the Polaris standard limited warranty for this vehicle.  
Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at the  
time of initial sale with the requirements of 40 CFR 1051 and, (2) free from defects in  
materials and workmanship that may keep it from meeting these requirements.  
The emissions warranty period for this vehicle begins on the date the vehicle is delivered  
to the original retail purchaser and ends 30 months (2.5 years) after that date, after 5000  
km (3100 miles), or after 500 hours of operation, whichever comes first.  
This emission-related warranty covers components whose failure would increase an en-  
gine’s emissions, including electronic controls, fuel injection, exhaust-gas recirculation,  
aftertreatment, or any other system utilized in this vehicle to control emissions. Replac-  
ing or repairing other components not covered by this emissions warranty or the standard  
warranty is the responsibility of the owner; including the parts, labor and other costs  
associated with recommended maintenance.  
The exclusive remedy for breach of this limited warranty shall be, at the exclusive option  
of Polaris, repair or replacement of any defective materials, components or products.  
THE REMEDIES SET FORTH IN THIS LIMITED 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.  
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY IM-  
PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICU-  
LAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY PERIOD  
DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS WARRANTIES  
NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how  
long an implied warranty lasts, so the above limitation may not apply if it is inconsistent  
with the controlling state law.  
This limited warranty excludes failures not caused by a defect in material or workman-  
ship. This limited warranty does not cover damage due to accidents, abuse or improper  
handling, maintenance or use. This limited warranty also does not cover any engine that  
has been structurally altered, or any engine that has been used in racing competition. This  
limited warranty also does not cover physical damage, corrosion or defects caused by  
fire, explosions or other similar causes beyond the control of Polaris.  
If you have any questions regarding your warranty rights and responsibilities, you  
should contact the Polaris Warranty Department at 1-888-704-5290.  
115  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE LOG  
Use the following chart to record periodic maintenance.  
DATE  
MILES (KM)  
TECHNICIAN  
SERVICE PERFORMED / COMMENTS  
116  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE LOG  
DATE  
MILES (KM)  
TECHNICIAN  
SERVICE PERFORMED / COMMENTS  
117  
Download from Www.Somanuals.com. All Manuals Search And Download.  
INDEX  
A
E
Age Restrictions . . . . . . . . . . . . . . . .  
Air Filter . . . . . . . . . . . . . . . . . . . . . 84  
Auxiliary Brake . . . . . . . . . . . . 37, 72  
6
Electrical Switches . . . . . . . . . . . . . 31  
Emissions Warranty . . . . . . . . . . . 115  
Engine Break-in . . . . . . . . . . . . . . . 41  
Engine Fogging . . . . . . . . . . . . . . 102  
Equipment Modifications . . . . . . . . 10  
Exhaust Emission Control System . 59  
B
Battery . . . . . . . . . . . . . . . . . . . . 91-97  
Battery Charging (Conventional) . . 95  
Battery Charging (Sealed) . . . . . . 96-97  
Battery Fluid (Conventional) . . . . . 95  
Battery Installation . . . . . . . . . . . . . 93  
Battery Removal . . . . . . . . . . . . . . . 92  
Battery Storage . . . . . . . . . . . . . . . . 94  
Belt Break-in . . . . . . . . . . . . . . . . . . 41  
Brake Lever . . . . . . . . . . . . . . . . . . 34  
Brake, Auxiliary . . . . . . . . . . . . . . . 72  
Brakes . . . . . . . . . . . . . . . . . . 35, 71-72  
Break-In Period . . . . . . . . . . . . . . . . 41  
F
Front Wheel Hub Tightening . . . . . 78  
Fuel Filter . . . . . . . . . . . . . . . . . . . . 38  
Fuel Safety . . . . . . . . . . . . . . . . . . . 26  
Fuel Stabilizer . . . . . . . . . . . . . . . . 101  
Fuel Tank . . . . . . . . . . . . . . . . . . . . 38  
Fuel Valve . . . . . . . . . . . . . . . . . . . . 38  
G
Gear Selector . . . . . . . . . . . . . . . . . . 39  
C
H
Camber and Caster . . . . . . . . . . . . . 72  
Carburetor . . . . . . . . . . . . . . . . . . . . 75  
Choke . . . . . . . . . . . . . . . . . . . . . . . 38  
Chrome Wheel Care . . . . . . . . . . . 100  
Cleaning and Storage . . . . . . . . 98-103  
Clutch Break-in . . . . . . . . . . . . . . . . 41  
Crankcase Emission Control System 59  
Handlebars . . . . . . . . . . . . . . . . . . . 74  
Hauling Cargo . . . . . . . . . . . . . . . 46-47  
Headlight Lamp Replacement . . . . . 82  
I
Indicator Lamp Replacement . . . . . 83  
Indicator Lights . . . . . . . . . . . . . . . . 32  
D
K
Drive Chain . . . . . . . . . . . . . . . . 79-81  
Drivetrain Break-in . . . . . . . . . . . . . 41  
Driving Downhill . . . . . . . . . . . . . . 52  
Driving in Reverse . . . . . . . . . . . . . 57  
Driving on Slippery Surfaces . . . . . 49  
Driving Over Obstacles . . . . . . . . . . 56  
Driving Procedures . . . . . . . . . . . . . 45  
Driving Safely . . . . . . . . . . . . . . . 45-58  
Driving Through Water . . . . . . . . . . 55  
Driving Uphill . . . . . . . . . . . . . . 50-51  
K-turn . . . . . . . . . . . . . . . . . . . . . . . 54  
L
Light Switches . . . . . . . . . . . . . . . . 32  
Lights . . . . . . . . . . . . . . . . . . . . . 82-83  
Lubrication Recommendations . . 64-65  
M
Main Switch . . . . . . . . . . . . . . . . . . 31  
Making Turns . . . . . . . . . . . . . . . . . 48  
118  
Download from Www.Somanuals.com. All Manuals Search And Download.  
INDEX  
N
S
Noise Emission Control System . . . 59  
Safe Riding Gear . . . . . . . . . . . . . . . 30  
Safety Decals and Locations . . . . 27-29  
O
Safety Training . . . . . . . . . . . . . . . . .  
6
Oil Change . . . . . . . . . . . . . . . . . . . 67  
Oil Check . . . . . . . . . . . . . . . . . . . . 66  
Oil Recommendations . . . . . . . . . . . 66  
Oil, Engine . . . . . . . . . . . . . . . . . 66-67  
Oil, Transmission . . . . . . . . . . . . 68-69  
Operator Safety . . . . . . . . . . . . . . . 6-25  
Override Switch . . . . . . . . . . . . . . . 31  
Sidehilling . . . . . . . . . . . . . . . . . . . 53  
Spark Arrestor . . . . . . . . . . . . . . . . . 90  
Spark Plugs . . . . . . . . . . . . . . . . . 85-86  
Specifications . . . . . . . . . . . . . 104-106  
Starting the Engine . . . . . . . . . . . 43-44  
Steering Assembly . . . . . . . . . . . . . 72  
Stop Switch . . . . . . . . . . . . . . . . . . . 31  
Storage Tips . . . . . . . . . . . . . . 101-103  
P
T
Parking Brake . . . . . . . . . . . . . . . . . 36  
Parking on an Incline . . . . . . . . . . . 58  
Periodic Maintenance Chart . . . . 60-63  
Polaris Products . . . . . . . . . . . . . . 107  
Pre Ride Inspection . . . . . . . . . . . . . 42  
PVT Break-in . . . . . . . . . . . . . . . . . 41  
PVT Drying . . . . . . . . . . . . . . . . . . 89  
PVT System . . . . . . . . . . . . . . . . 88-89  
Taillight/Brakelight Lamp  
Replacement . . . . . . . . . . . . . . 83  
Throttle Cable Freeplay . . . . . . . . . . 73  
Throttle Lever . . . . . . . . . . . . . . . . . 33  
Tire Tread Depth . . . . . . . . . . . . . . . 78  
Toe Alignment . . . . . . . . . . . . . . . . 70  
Towing Capacities . . . . . . . . . . . . . . 46  
Transmission Gear Selector . . . . . . . 39  
Transmission Oil . . . . . . . . . . . . . . . 68  
Transmission Oil Change . . . . . . . . 69  
Transmission Oil Check . . . . . . . . . 68  
Transporting the ATV . . . . . . . . . . 103  
Turning Around on a Hill . . . . . . . . 54  
R
Rear Drive Chain Slack . . . . . . . . 80-81  
Rear Spring . . . . . . . . . . . . . . . . . . . 72  
Recoil Housing . . . . . . . . . . . . . . . . 86  
Recoil Starter . . . . . . . . . . . . . . . . . 40  
V
Vehicle Identification Numbers . . . . .  
5
Vehicle Immersion . . . . . . . . . . . . . 87  
W
Washing the Vehicle . . . . . . . . . . 98-99  
Wheel Installation . . . . . . . . . . . . . . 77  
Wheel Nut Torque Specifications . . 77  
Wheel Removal . . . . . . . . . . . . . . . 76  
Wheels . . . . . . . . . . . . . . . . . . . . 76-78  
119  
Download from Www.Somanuals.com. All Manuals Search And Download.  

Peerless Industries TV Mount PF632 User Manual
Philips Cell Phone 625 User Manual
Philips Cell Phone CT9A9WBLK User Manual
Philips Flat Panel Television PF996542 User Manual
Philips Styling Iron HP8309 00 User Manual
Pioneer CD Player FH P6200 User Manual
Pioneer DVD Player DVH P5650MP User Manual
Planet Technology Network Card PL 101E User Manual
Premier Mounts TV Mount PWM 503 User Manual
Presonus Audio electronic Stereo Amplifier ADl 600 User Manual