Polaris Mv700 Users Manual Mv7
MV700 to the manual 1fcda016-9024-437f-8c8d-07a38e4bb211
2015-01-26
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WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. 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 Copyright 2006 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. 2007 MV700 Owner’s Manual P/N 9921217 2 TABLE OF CONTENTS VEHICLE IDENTIFICATION NUMBERS . . . . . . . . . . . 5 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . 62 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 POLARIS PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . 111 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 114 WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 MAINTENANCE RECORD . . . . . . . . . . . . . . . . . . . . 124 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 3 4 VEHICLE IDENTIFICATION NUMBERS Record your vehicle’s identification numbers in the spaces provided. 2 1 Vehicle Model Number: Frame VIN (1): Engine Serial Number (2): 5 SAFETY Operator Safety WARNING Failure to follow the warnings contained in this manual can result in serious injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions. Read and understand your owner’s manual and all warnings before operating a Polaris ATV. Age Restrictions This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age. Know Your Vehicle As the operator of the vehicle, you are responsible for your personal safety, the safety of others, and the protection of our environment. Read and understand your owner’s manual, which includes valuable information about all aspects of your vehicle, including safe operating procedures. Safety Training 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 this vehicle in your area. We strongly advise you to strictly follow the recommended maintenance program outlined in your owner’s manual. This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals. 6 Operator Safety 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 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 safety training course. S Always avoid operating an ATV on paved surfaces, including sidewalks, 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 footrests of the ATV during operation. S Always travel slowly and use extra caution when operating on unfamiliar 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 manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speeds. 8 Operator Safety 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 terrain carefully before ascend a hill. Never climb hills with excessively 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 possible. 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 turning 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 procedure for braking described in this manual. Always dismount on the uphill side, or to either side if the ATV is pointed straight uphill. Turn the ATV around and remount following the procedure described in this manual. 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 skidding 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 sudden movements, and maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make sudden throttle changes. 9 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 operating 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 accessories. 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. FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety Commission at 1-800-638-2772, or visit www.cpsc.gov, visit www.atvsafety.org, or call Polaris at 1-800-342-3764. 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: 10 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. Operator Safety 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 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 Operator Safety SAFETY WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN The ATV could collide with another vehicle. HOW TO AVOID THE HAZARD Never operate the ATV on any public street, road or highway, including dirt and gravel roads. In many states it’s illegal to operate ATVs on public streets, roads and highways. WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident. Operating without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident. HOW TO AVOID THE HAZARD Always wear an approved helmet that fits properly. Always wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket, and long pants. 13 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 Operator Safety 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 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 Operator Safety SAFETY WARNING POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Operating on excessively rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you’ve learned and practiced the skills necessary to control the ATV on such terrain. Always use extra caution on rough, slippery or loose terrain. WARNING POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner’s manual. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speed. 17 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle may overturn. HOW TO AVOID THE HAZARD Never operate on hills too steep for the ATV or for your abilities. Never operate the ATV on hills steeper than 25_. Practice on smaller hills before attempting large hills. WARNING POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner’s manual. Always check the terrain carefully before ascending any hill. Never operate the ATV on hills steeper than 25_. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly while traveling uphill. The ATV could flip over backwards. Never go over the top of any hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill. 18 Operator Safety 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 56. 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 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 57. 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 Operator Safety 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 57. 21 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 Operator Safety 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 58), 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 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 49. 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 Operator Safety SAFETY 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 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 1 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 2 Oceania bear the ECE 22.05 label. The ECE mark consists of a circle surrounding the 5 letter E, followed by the 4 distinguishing number of the country which has 051039 granted approval. The 0006.031 approval number and serial number will also be displayed on the label. 3 E 4 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. 26 CONTROLS Electrical Switches WARNING Activating the override switch while the throttle is open can cause loss of control, resulting in severe injury or death. Do not activate the override switch while the throttle is open. 6 5 4 2 1 3 Mode/Reverse Override Switch (1) - This vehicle is equipped with a reverse speed limiter system. To gain additional power while backing, depress the override switch. The override switch also allows activation of AWD in reverse, if the AWD switch is on. This switch is also used to toggle through the different modes of the rider information center. See page 38. Engine Stop Switch (2) - The engine will not start or run when the switch is in the OFF position. Its purpose is to provide the operator with a quick means of engine shutdown in case of an emergency. 2 Ignition Switch Lever (3) - To start the engine, slide the stop switch to the center RUN position and turn the ignition switch lever clockwise past the ON position. Release the lever when the engine starts. NOTE: Both the ignition switch and the emergency engine stop switch will shut off all electrical power to the vehicle, including lights. To stop the engine, slide the stop switch either right or left to the OFF position. Infrared Light Switch (4) - Use this switch to activate the infrared lights (if equipped). When the infrared lights are turned on, all other lights on the vehicle are turned off. Front/Rear Winch Switch (5) - Use the switch on the pod to select either the front or rear winch. Winch Operation Switch (6) - After selecting either the front or rear winch with the switch on the pod, use the handlebar switch to operate the winch. Operation instructions can be found in the winch operation guide provided by the winch manufacturer. 27 CONTROLS WARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death. Never start or operate an ATV with a sticking or improperly operating throttle. Always contact your dealer for service if throttle problems arise. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation. Always check the lever for free movement and return before starting the engine. Also check occasionally during operation. Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle lever (1). The throttle lever is spring loaded. Engine speed returns to idle when the lever is released. This ATV is equipped with Polaris 1 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. 28 Light Switches CONTROLS The light switch is located on the left handlebar. It’s used to turn the lights on and off and to switch the lights from HI to LO. To operate the lights, the ignition switch lever must be in the ON position and the stop switch must be in the RUN position. WARNING Operating the ATV on streets or roads, especially in darkness, could result in an accident and serious injury or death. Your ATV is not equipped with highway-approved lights. It’s designed for and must be used for off-road use only. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness. Brake Lever The front and rear brakes are applied 1 by squeezing the brake lever (1) toward the handlebar. The front and rear brakes are hydraulically activated disc type brakes that are activated by only one lever. Always test brake lever travel and master cylinder fluid level before riding. When squeezed, the lever should feel firm. Any sponginess would indicate a possible fluid leak or low master cylinder fluid level, which must be corrected before riding. Contact your dealer for proper diagnosis and repairs. WARNING Operating the ATV with a spongy brake lever can result in loss of braking, which could cause an accident. Never operate the ATV with a spongy-feeling brake lever. 29 CONTROLS Master Cylinder The brake fluid in the master cylinder (1), which is located on the left handlebar, should be checked before each ride. 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. NOTE: 1 2 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. See page 111 for the part numbers of Polaris products. WARNING After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. 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. 30 Parking Brake CONTROLS 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. Locking the Parking Brake 1 1. Place the transmission in PARK. 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the park brake lock (1) forward to engage the brake. Release the brake lever. 4. 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. Always 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. 31 CONTROLS Auxiliary Brake WARNING Aggressively applying the auxiliary brake when backing down a hill 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. Your Polaris ATV has an auxiliary brake (1) for added safety. It’s located on the inside of the right floor board and is operated by the right foot. The auxiliary brake serves as a backup to the main brake system if the main system becomes inoperative. If the rear wheels slide while using the auxiliary brake, reduce brake pedal pressure to brake the rear wheels without skidding. 1 Brake Fluid Level Check the brake fluid level frequently for the auxiliary brake system. The reservoir is located under the seat or near the auxiliary brake. Maintain the fluid level between the maximum and minimum marks. 32 CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 47 for correct choke and throttle settings during starting. Fuel Requirements Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. Fuel Valve The fuel valve (1) is located on the left side panel. OFF: Turn the fuel valve off for vehicle storage and when transporting. REAR TANK: We recommend using the rear tank fuel supply first. Switch to the front tank when the rear tank is empty. It will be easier to monitor remaining fuel at the front tank gauge. FRONT TANK: Use the front tank fuel supply when the rear tank is empty. NOTE: REAR TANK OFF FRONT TANK 2 1 There is no reserve fuel supply on this vehicle. When both fuel tanks are empty, the vehicle will not operate. Fuel Tanks The front fuel tank filler cap (2) is located directly below the handlebar. The rear fuel tank and filler cap (3) are located behind the seat, under the rear rack. 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. 3 33 CONTROLS Automatic Transmission Gear Selector The transmission gear selector (1) is located on the right side of the vehicle. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park 1 H L N R P To shift into HIGH or PARK, apply the auxiliary brake to activate the high/park lock-out mechanism. When shifting out of HIGH or PARK, it’s not necessary to apply the brake. CAUTION Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage. To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear. Apply the auxiliary brake before shifting into HIGH or PARK. Whenever the ATV is left unattended, always place the transmission in PARK and lock the parking brake. Belt Life To extend belt life, use low forward gear in heavy pulling situations and when operating at less than seven miles per hour for extended periods of time. 34 Recoil Starter FEATURES 2 If the battery has been drained or damaged and cannot start the 1 engine, use of the recoil starter (1) will allow vehicle operation until repairs can be made. The recoil starter is located on the right side of the machine. Polaris 4-cycle engines are equipped with automatic decompressors. This makes recoil starting possible by reducing the amount of compression during starting. The decompressor senses when the engine is spinning fast enough to start and restores compression when running. 1. Position the vehicle on a level surface. 2. Lock the parking brake. 3. Shift the transmission into neutral. 4. Move the engine stop switch to RUN and the ignition switch lever to ON. NOTE: If the engine is cold, use the choke as outlined on page 47. 5. 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. 6. Allow the recoil rope to rewind into the recoil assembly, then pull the rope abruptly and forcefully to start the engine. 7. Repeat steps 5-6 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. 35 FEATURES Run-Flat Tires This ATV is equipped with run-flat tires, which permit limited operation with a flat tire. However, ATV load capacity is reduced when tire air pressure is lost. Remove cargo from the racks and do not tow a load with flat tires. Vehicle characteristics, including braking and handling, may also be affected by operating with flat tires. If you must operate the vehicle with a flat tire, drive no further and no faster than necessary, and travel on smooth and level terrain whenever possible. WARNING Failure to reduce travel distance, vehicle speed and cargo weight when air pressure is lost in run-flat tires could result in loss of control or tire damage. This could lead to serious injury or death. If you must operate the vehicle with flat tires, remove all cargo and towed loads from the ATV, and do not exceed 50 miles (80 km) at 25 MPH (40 km/h). Have the tire(s) inspected by an authorized Polaris dealer as soon as possible and before further use. Winches Your vehicle is equipped with both a front (1) and a rear (2) winch. These winches operate independently. Use the pod switch to select one of the winches. Use the handlebar switch to operate the selected winch. Refer to the winch manufacturer’s Basic Guide to Winching Techniques, provided with your ATV, for complete winch operation instructions. 36 2 1 All Wheel Drive (AWD) System FEATURES Polaris 4-wheel drive ATVs are equipped with a unique, Polaris-exclusive, All Wheel Drive (AWD) system, which is activated by a switch (1) on the right handlebar. 1 When the switch is off, the ATV is in 2-wheel drive at all times. When the switch is on, the ATV is in AWD and the AWD indicator light in the instrument cluster will be on. When in AWD, the demand drive unit will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the demand drive unit will automatically disengage. NOTE: The override switch allows activation of AWD in reverse if the AWD switch is on. See page 27. There is no limit to the length of time the vehicle may remain in AWD. Engaging All-Wheel Drive (AWD) The AWD switch may be turned on or off while the vehicle is moving. Initially, the vehicle’s electronic system will not enable the AWD until the engine RPM is below 3100. Once enabled, the AWD remains enabled until the AWD switch is turned off. If the switch is turned off while the demand drive unit is moving, it will not disengage until the rear wheels regain traction. Engage the AWD switch before getting into conditions where front wheel drive may be needed. If the rear wheels are spinning, release the throttle before switching to AWD. CAUTION Switching to AWD while the rear wheels are spinning may cause severe drive shaft and gearcase damage. Always switch to AWD while the rear wheels have traction or are at rest. 37 FEATURES Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in miles or kilometers as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV’s speed to approximately 7-9 mph. Refer to page 27 for additional information. 3 2 1 1. Rider Information Center 2. Speedometer needle - in addition to showing vehicle speed, the needle flashes when a warning condition exists. 3. Speedometer CAUTION High water pressure may damage ATV components. Wash the ATV by hand or with a garden hose using mild soap. Certain products, including insect repellents and chemicals, will damage the speedometer lens and other plastic surfaces. Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens. Immediately clean off any gasoline that splashes on the instrument cluster. 38 Instrument Cluster FEATURES Rider Information Center The rider information center is located in the instrument cluster. All segments will light up for 2.5 seconds at start-up. NOTE: If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the cluster’s electrical system. If this occurs, take the ATV to your Polaris dealer for proper diagnosis. 1. Gear Indicator - This indicator displays gear shifter position: 4 5 6 3 H = High Range 7 L = Low Range N = Neutral 8 2 R = Reverse P = Park 2. AWD Indicator - This indicator illuminates when the AWD switch is 9 in the AWD position. 1 3. Engine Hour Display Indicator 4. Service Interval/Diagnostic Mode Indicator 5. Low Battery and Over Voltage - This warning usually indicates that the ATV is being operated at an RPM too low to keep the battery charged. A low battery warning may also occur under normal operation if the machine is at idle and high electrical load (lights, cooling fan, accessories) is applied. Drive at a higher RPM or recharge the battery to clear the warning. 6. Odometer/Tachometer/Tripmeter/ Hour Meter 7. Fuel Gauge - The segments of the fuel gauge indicate the level of fuel in the front tank only. Since use of the rear tank is recommended for normal operation, the rear tank may already be empty. Refuel immediately if the last segment of the fuel gauge clears. 8. Check Engine Warning Indicator - The word HOT displays if the engine overheats. Do not operate the ATV if this warning appears. Serious engine damage could result 9. Mode Indicator 39 FEATURES Instrument Cluster Rider Information Center Standard Modes Use the MODE button to toggle through the mode options. The reverse override button is also the MODE button. See page 27. NOTE: The transmission cannot be in reverse when using this feature. Odometer Mode The odometer records the miles traveled by the ATV. Trip Meter Mode The trip meter records the miles traveled by the ATV on each trip if it’s reset before each trip. To reset the trip meter, select the trip meter mode. Press and hold the mode button (override button) until the total changes to 0. NOTE: In the Rider Information Center, the trip meter display contains a decimal point, but the odometer displays without a decimal point. Hour Meter Mode This mode logs the total hours the engine has been in operation. Tachometer Mode The engine RPM is displayed digitally. NOTE: 40 Small fluctuations in the RPM from day to day may be normal because of changes in humidity, temperature, elevation and electrical loads. Instrument Cluster FEATURES Rider Information Center Diagnostic Mode The wrench icon will display when the gauge is in the diagnostic mode. To exit the diagnostic mode, turn the ignition switch off and on. Any movement of the tires will also cause the gauge to exit the diagnostic mode. To enter the diagnostics mode: 1. Turn the ignition switch off and wait 10 seconds. 2. Lock the parking brake. 3. Place the transmission in neutral. 4. Hold the mode/reverse override button and turn the ignition switch on. Release the switch as soon as the display is activated. 5. Use the mode button to toggle through the diagnostic screens. 41 FEATURES Instrument Cluster Rider Information Center Diagnostic Mode Battery Voltage Screen View this screen to check battery voltage level. Tachometer Screen View the tachometer to check engine speed. AWD Diagnostic Screen The gauge indicates whether or not current is flowing through the AWD coil (only on models with switchable AWD). This screen is for informational purposes only. Please see your dealer for all major repairs. Gear Circuit Diagnostic Screen This screen displays the resistance value (in ohms) being read at the gear switch input of the gauge. This screen is for informational purposes only. Please see your dealer for all major repairs. Programmable service interval When the hours of engine operation equal the programmed service interval setting, the wrench icon will flash for 5 seconds each time the engine is started. When this feature is enabled, it provides a convenient reminder to perform routine maintenance. See page 43. NOTE: 42 The service interval is programmed at 50 hours at the factory. Instrument Cluster FEATURES Rider Information Center Diagnostic Mode Programmable service interval To enable or disable the service interval: 1. Enter the diagnostic mode. 2. Toggle to the service interval screen. 3. Press and hold the mode button for about 7 seconds, until either ON or OFF appears in the Rider Information Center, depending on your preference. To reset the service interval: 1. Enter the diagnostic mode. 2. Toggle to the service interval screen. 3. Press and hold the mode button for 2--3 seconds, until the wrench icon flashes. Release the button. 4. Press and release the mode button once to advance the setting by one hour. Press and hold the mode button to advance the hours quickly. NOTE: If you scroll past the intended number, press and hold the button until the hours cycle back to zero. 5. When the desired setting is displayed, wait until the wrench icon stops flashing. The new service interval is now programmed. Miles/Kilometers toggle The display in the tripmeter and odometer can be changed to display either standard or metric units of measurement. 1. Enter the diagnostic mode. 2. Toggle to the screen that displays either kilometers (KM) or miles (MP). 3. Press and hold the mode button until the letters flash, then press and release the button once. When the display stops flashing, the mode has been set. 43 OPERATION 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. 44 Break-In Period OPERATION 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. Do not operate at full throttle or high speeds for extended periods during the first three hours of use. Engine and Drivetrain Break-in 1. Fill the fuel tanks with gasoline. See page 33. 2. Check the oil reservoir level on the dipstick. See page 70. Add oil if necessary to maintain the level between the safe and add marks. 3. Drive slowly at first. Select an open area that allows room to familiarize yourself with vehicle operation and handling. 4. Vary the throttle positions. Do not operate at sustained idle. 5. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride inspection checklist. See page 46. 6. Pull only light loads. 7. During the break-in period, change both the oil and the filter at 20 hours or one month. PVT Break-in (Clutches/Belt) A proper break-in of the clutches and drive belt will ensure a longer life and better performance. Break in the clutches and belt by operating at slower speeds during the break-in period as recommended. Pull only light loads. Avoid aggressive acceleration and high speed operation during the break-in period 45 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 Ensure proper operation 29, 80 Brake fluid Ensure proper level 30 Auxiliary brake Ensure proper operation 32 Front suspension Inspect, lubricate if necessary 68 Rear suspension Inspect, lubricate if necessary 68 Steering Ensure free operation Tires Inspect condition and pressure 83 Wheels / fasteners Inspect, ensure fastener tightness 84 Frame nuts, bolts, fasteners Inspect, ensure tightness Fuel and oil Ensure proper levels 70 Coolant level (if applicable) Ensure proper level -- Coolant hoses (if applicable) Inspect for leaks Throttle Ensure proper operation Indicator lights / switches Ensure operation 29 Engine stop switch Ensure proper operation 27 Air filter, pre-filter Inspect, clean 85 Air box sediment tube Drain deposits whenever visible Headlamp Check operation, apply Polaris dielectric grease when lamp is replaced Check operation, apply Polaris dielectric grease when lamp is replaced Wear helmet, goggles, protective clothing Brake light / tail lamp Riding gear 46 -- -- -28,103 -86 89 26 Starting the Engine OPERATION WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Lock the parking brake. NOTE: The starter interlock will prevent the engine from starting if the transmission is in gear and the brake is not engaged. 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 (1) out until it stops. 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 1 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 clockwise. 7. Move the engine stop switch to RUN. NOTE: Do not press the throttle while starting the engine. 47 OPERATION Starting the Engine 8. Turn the ignition lever past the ON position to engage the starter. Activate the starter for a maximum of five seconds, releasing the lever when the vehicle starts. 9. If the engine does not start, return the ignition lever to the OFF position and wait five seconds. Activate the starter for another five seconds if necessary. 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 or stops, 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. Cold Weather Operation If the ATV is used year-round, check the oil level frequently. A rising oil level could indicate the accumulation of contaminants such as water or excess fuel in the crankcase. Water in the crankcase can lead to engine damage and must be drained. Water accumulation increases as outside temperature decreases. See your Polaris dealer for engine heater kits, which provide quicker warm-ups and easier starting in colder weather. 48 Hauling Cargo 1/3 OPERATION 2/3 Do not exceed the weight capacities specified for the vehicle. Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as possible. When operating over rough or hilly terrain, reduce speed and cargo weight to maintain stable driving conditions. Do not obstruct the headlight beam with cargo. Use low forward gear when hauling or towing heavy cargo to extend belt life. Refer to the specifications section beginning on page 112 for capacities. Towing Loads Always attach a towed load to the hitch point. If towing a load, reduce rear rack cargo weight by the amount of tongue weight. The combination of rear rack cargo weight and tongue weight must not exceed the rear rack capacity. See page 112. Maximum Towing Capacities Towed Load (Level Ground) 1500 lbs. (681 kg) Towed Load (15_ Incline) 850 lbs. (386 kg) Vertical Hitch Weight 150 lbs. (68.1 kg) 49 OPERATION Hauling Cargo WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo: S REDUCE SPEED AND ALLOW GREATER DISTANCES 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 possibility of vehicle overturn. S CARRY LOADS 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. S SECURE ALL LOADS 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 centered, securely fasten the load and operate with extra caution. Always attach the tow load to the hitch point designated for your vehicle. S HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations that may require backing downhill. S USE EXTREME CAUTION when operating with loads that extend over the rack sides. Stability and maneuverability may be adversely affected, causing the vehicle to overturn. S DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying 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 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. 50 Driving Procedures OPERATION 1. Wear protective riding gear. See page 26. 2. Sit upright with both feet on the footrests and both hands on the handlebars. 3. Start the engine and allow it to warm up. 4. Shift the transmission into gear. 5. Check your surroundings and determine your path of travel. 6. Release the parking brake. 7. Slowly depress the throttle with your right thumb and begin driving. 8. Drive slowly. Practice maneuvering and using the throttle and brakes on level surfaces. 51 OPERATION Making Turns Your ATV is equipped with a rear axle that drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly. To 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. 52 Driving on Slippery Surfaces OPERATION 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. Engage AWD before wheels begin to lose traction. 3. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns, which can cause skids. 4. Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward. CAUTION Severe damage to drive train may occur if the AWD is engaged while the wheels are spinning. Always allow the rear wheels to stop spinning before engaging AWD, or engage AWD before wheels begin to lose traction. WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control, accident, and serious injury or death. Never apply the brakes during a skid. Do not operate on excessively slippery surfaces. Always reduce speed and use additional caution. 53 OPERATION Driving Uphill 25_ Maximum Whenever traveling uphill, follow these precautions: 1. Drive straight uphill. 2. Avoid steep hills (25_ maximum). 3. Keep both feet on the footrests. 4. Shift your weight uphill. 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. 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. 54 Driving on a Hillside (Sidehilling) OPERATION 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 dangerous and should be avoided if at all possible. If you encounter a situation where sidehilling is necessary, follow these precautions: 1. Slow down. 2. Shift your weight uphill. 3. Keep your feet on the footrests. 4. Steer slightly into the hill to maintain vehicle direction. NOTE: If the vehicle begins to tip, quickly turn the front wheel downhill, if possible, or dismount on the uphill side immediately! 55 OPERATION Driving Downhill WARNING Excessive speed when traveling downhill can cause loss of control and serious injury or death. Slow down. Applying the brakes too firmly may cause the rear wheels to lock, which could result in loss of control and serious injury or death. Apply the brakes gradually. When driving downhill, follow these precautions: 1. Shift your weight uphill. 2. Drive straight downhill. 3. Slow down. 4. Squeeze the brake lever gradually. NOTE: 56 Before operating your ATV, learn how to use the auxiliary brake for emergency situations (if single-lever brakes become inoperable). Turning Around on a Hill OPERATION If the vehicle stalls while climbing a hill, never back down the hill! Use the K-turn to turn around. 8 ft. (2.4 m) 1. Stop the vehicle and lock the parking brake while keeping body weight uphill. 2. Leave the transmission in forward and stop 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 service brake, 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. 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 service brake, until the vehicle is on more level ground. 57 OPERATION Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests (1). Follow these procedures when operating through water: 1. Determine water depths and current before crossing. 1 2. Choose a crossing where both banks have gradual inclines. 3. Proceed slowly, avoiding rocks and obstacles. 4. After crossing, dry the brakes by applying light pressure to the lever until braking action is normal. After running the vehicle in water, it’s critical to have it serviced as outlined in the maintenance chart. See page 63. The following areas need special attention: engine oil, transmission oil, demand drive fluid, rear gearcase oil 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 92. Have the vehicle serviced by your dealer at the first opportunity. 58 Driving Over Obstacles OPERATION 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. 59 OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles. 6. Never open the throttle suddenly. 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: Your 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. 60 Parking on an Incline OPERATION Avoid parking on an incline if possible. If it’s unavoidable, follow these precautions: 1. Stop the engine. 2. Place the transmission in PARK. 3. Lock the parking brake. 4. Always block the rear wheels on the downhill side. 5. Turn the fuel valve off. 61 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. 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. Adjustment to engine idle is the only adjustment Polaris recommends that the operator perform. Any other adjustments should be performed by an authorized Polaris dealer. The emissions label is located on the air box. Electromagnetic Interference This spark ignition system complies with Canadian ICES--002. This vehicle complies with European directives 97/24/EC and 89/336/EEC. 62 Periodic Maintenance Chart MAINTENANCE Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. NOTE: Service and adjustments are 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. 63 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key " E J Perform these procedures more frequently for vehicles subjected to severe use. Emission Control System Service (California) Have an authorized Polaris dealer perform these services. WARNING Improperly performing the procedures marked with a J could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. 64 Periodic Maintenance Chart MAINTENANCE Perform all services at whichever maintenance interval is reached first. Item Maintenance Interval (whichever comes first) Hours Calendar Miles (Km) J Steering -- Pre-Ride -- " Front suspension -- Pre-Ride -- " Rear suspension -- Pre-Ride -- Tires Remarks Make adjustments j as needed See Pre ed. Pre-Ride Ride Checklist on page 46. -- Pre-Ride -- " Brake fluid level -- Pre-Ride -- " Brake lever travel -- Pre-Ride -- Brake system -- Pre-Ride -- Wheels/fasteners -- Pre-Ride -- Frame fasteners -- Pre-Ride -- " Engine oil level -- Pre-Ride -- " Air filter, pre-filter -- Daily -- Inspect; clean often " Air box sediment -- Daily -- Drain deposits when visible Coolant -- Daily -- Check level daily, change coolant every 2 years Headlamp/tail lamp -- Daily -- Check operation -- Weekly -- Inspect; replace as needed -- Weekly -- Drain water as needed, check often if operating in wet conditions 10 H Monthly 100 (160) Inspect periodically E tube " Air filter, E main element Recoil housing " Brake pad wear J 20 H Monthly 200 (320) Check terminals; clean; test " Demand drive Battery 25 H Monthly 250 (400) Inspect level; change yearly " Rear gearcase oil 25 H Monthly 250 (400) Inspect level; change yearly " Transmission oil 25 H Monthly 250 (400) Inspect level; change yearly " Engine breather 25 H Monthly 250 (400) Inspect; clean if needed fluid E filter (if equipped) Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service J Have an authorized Polaris dealer perform these services. " 65 MAINTENANCE Periodic Maintenance Chart Item " General Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) 50 H 3M 500 (800) Lubricate all fittings, pivots, cables, etc. 50 H 6M 500 (800) Drain bowl periodically and prior to storage J Throttle Cable/ 50 H 6M 500 (800) Inspect; adjust; lubricate; replace if necessary J Choke cable 50 H 6M 500 (800) Inspect; adjust; lubricate; replace if necessary 50 H 6M 500 (800) Inspect ducts for proper sealing/air leaks Drive belt 50 H 6M 500 (800) Inspect; adjust; replace as needed Cooling system 50 H 6M 1000 (1600) Inspect coolant strength seasonally; pressure test system yearly " Engine oil change 100 H 6M 1000 (1600) Perform a break-in oil change at one month " Oil filter change 100 H 6M 1000 (1600) Replace with oil change J Valve clearance 100 H 12 M 1000 (1600) Inspect; adjust J Fuel system/filter 100 H 12 M 1000 (1600) " Radiator 100 H 12 M 1000 (1600) Check for leaks at tank cap, lines, fuel valve, filter, pump, carburetor; replace lines every two years Inspect; clean external surfaces " Cooling hoses 100 H 12 M 1000 (1600) Inspect for leaks " Engine mounts 100 H 12 M 1000 (1600) Inspect 100 H 12 M 1000 (1600) Inspect lubrication Carburetor float bowl E ETC Switch E E Carburetor air intake ducts/ flange E E (if applicable) (if applicable) Exhaust muffler/ pipe Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service J Have an authorized Polaris dealer perform these services. " 66 Periodic Maintenance Chart Item MAINTENANCE Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) J Spark plug 100 H 12 M 1000 (1600) Inspect; replace as needed J Ignition Timing 100 H 12 M 1000 (1600) Inspect " Wiring 100 H 12 M 1000 (1600) J Clutches (drive 100 H 12 M 1000 (1600) Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc. Inspect; clean; replace worn parts J Front wheel 100 H 12 M 1000 (1600) Inspect; replace as needed J Brake fluid 200 H 24 M 2000 (3200) Change every two years 300 H 36 M 3000 (4800) Clean out E E and driven) bearings Spark arrestor Winch System -- Refer to the operator’s guide provided by the winch manufacturer. E Idle speed -- Adjust as needed J Toe adjustment -- Inspect periodically; adjust when parts are replaced -- Adjust as needed Headlight aim Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service J Have an authorized Polaris dealer perform these services. " 67 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 63. Items not listed in the chart should be lubricated at the General Lubrication interval. Item Lube Method Engine Oil Polaris Premium 4 Synthetic 0W40 Add to proper level on dipstick. Brake Fluid DOT 4 Only Maintain level between fill lines. See page 30. Transmission Oil Polaris AGL Synthetic Gearcase Lube See page 74. Demand Drive Fluid (Front Gearcase) Demand Drive LT Premium Fluid See page 73. Rear Gearcase Oil Premium ATV Angle Drive Fluid See page 75. General Lubrication Polaris Premium All Season Grease Front Prop Shaft Yoke (Fig. 1) Polaris Premium U--Joint Lube Grease fittings (3 pumps maximum) every 500 miles, before long periods of storage, or after pressure washing or submerging. (Fig. 1) 68 MAINTENANCE Premium 4 Synthetic Lubricant Polaris Premium 4 All Season synthetic engine oil has been specially formulated for use in Polaris 4-cycle engines. It’s a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection. See page 111 for the part numbers of Polaris products. Premium 4 possesses unsurpassed film strength over the widest possible temperature range. It resists viscosity and frictional breakdown in ambient temperatures from -40° F. to 120° F. (-40 to +49° C.) Its exceptional frictional properties result in more efficient operation, more power output and lower fuel consumption. Although Polaris Premium 4 is the only oil recommended for use in this engine, use of any API certified SH oil is allowable as long as it’s 0W-40. Oil may need to be changed more frequently if Polaris Premium 4 is not used. Follow the manufacturer’s recommendations for ambient temperature operation. CAUTION Mixing brands or using a non-recommended oil may cause serious engine damage. We recommend the use of Polaris Premium 4 synthetic Oil or another 0W-40 API certified SH oil. Never substitute or mix oil brands. 69 MAINTENANCE Oil Check The dipstick/oil fill (1) is located on the engine on the left side of the ATV. Do not start the engine before the oil check. NOTE: A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase. If the oil level is over the full/safe mark, change the oil immediately. 1. Position the vehicle on a level surface. 2. Remove the dipstick and wipe it dry with a clean cloth. NOTE: Lift the lever lock (2) to remove the dipstick. 3. Reinstall the dipstick completely, but do not lock it. The dipstick must be completely seated. 4. Remove the dipstick and check the oil level. Maintain the oil level 2 between the SAFE and ADD marks (3). Do not overfill. NOTE: Due to the dipstick entry angle into the crankcase, the oil level will read higher on the bottom side of the dipstick. Always read the level on the upper surface (4) of the dipstick. 5. After reinstalling the dipstick, seat the lever lock. 70 1 ADD 8 OZ SAFE 3 4 Oil and Filter Change MAINTENANCE Change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 63. Always install a new filter when changing the oil. 1. Position the vehicle on a level surface. 2. Run the engine for two to three minutes until warm. Stop the engine. 3. Clean the area around the drain plug. 4. Place a drain pan beneath engine crankcase and remove the drain plug. CAUTION Hot oil can cause serious burns. Do not allow hot oil to touch skin. 5. Allow the oil to drain completely. 6. Replace the sealing washer on the drain plug. NOTE: The sealing surfaces on drain plug and crankcase should be clean and free of burrs, nicks or scratches. 7. Reinstall the drain plug and torque to 20 ft. lbs. (27 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 o-ring on the new filter with a film of fresh engine oil. Check to make sure the o-ring 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 two quarts (1.9 l) of recommended oil. 13. Place the gear selector in PARK 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. Re-check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick. 16. Dispose of used filter and oil properly. 71 MAINTENANCE Gearcase Specification Chart Gearcase Lubricant Capacity Fill Plug Torque Drain Plug Torque Main Gearcase (Transmission) Premium AGL Synthetic Gearcase Lube 15.2 oz. (450 ml) 14 ft. lbs. (19 Nm) 14 ft. lbs. (19 Nm) Demand Drive Unit (Front Gearcase) Demand Drive LT Premium Fluid 9 oz. (265 ml) 8-10 ft. lbs. (11-14 Nm) 11 ft. lbs. (15 Nm) Rear Gearcase Premium ATV Angle Drive Fluid 10 oz. (300 ml) Side plug 16 ft. lbs. (22 Nm) 14 ft. lbs. (19 Nm) 72 MAINTENANCE Front Gearcase (Demand Drive) Fluid Always check and change the demand drive fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 66. We recommend the use of Demand Drive LT Premium Fluid. Use of other fluids may result in improper operation of components. Refer to the Gearcase Specifications Chart on page 72 for recommended lubricants, capacities and torque specifications. See page 111 for the part numbers of Polaris products. The fill plug (1) is 1 located on the right side of the demand drive unit. The drain plug (2) is located on the bottom right side of the unit. Maintain the fluid level at the bottom of the fill hole threads (3). 3 Fluid Check 2 1. Position the vehicle on a level surface. 2. Remove the fill plug. Check the fluid level. 3. Add the recommended demand drive fluid as needed to bring the level to the bottom of the fill hole threads. 4. Reinstall the fill plug. Torque to specification. Fluid Change 1. 2. 3. 4. 5. 6. 7. 8. Position the vehicle on a level surface. Remove the fill plug. Place a drain pan under the demand drive unit. Remove the drain plug. Allow the fluid to drain completely. Clean and reinstall the drain plug. Torque to specification. Add the recommended fluid. Reinstall the fill plug. Torque to specification. Check for leaks. Dispose of used fluid properly. 73 MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 63. Maintain the transmission oil level at the bottom of the fill plug hole (1). Refer to the Gearcase Specifications Chart on page 72 for recommended lubricants, capacities and torque specifications. See page 111 for the part numbers of Polaris products. The transmission oil fill plug (2) is located on the right side of the ATV behind the footwell. The transmission drain plug (3), is located on the bottom left-hand side of the gearcase. 2 1 3 Oil Check 1. 2. 3. 4. Remove the footwell (see page 82). Remove the fill plug and check the oil level. Reinstall the fill plug. Torque to specification. Reinstall the footwell. Oil Change 1. Remove the footwell (see page 82). 2. Remove the drain plug and drain the oil into a drain pan. Dispose of properly. 3. Clean and reinstall the drain plug. Torque to specification. 4. Remove the fill plug and add the recommended fluid. 5. Reinstall the fill plug. Torque to specification. 6. Check for leaks. 7. Reinstall the footwell. 74 Rear Gearcase Oil MAINTENANCE The rear gearcase has two fill plugs. The rear fill plug is located on the rear of the gearcase and is not easily accessible. The side fill plug (1) is located on the 1 left side of the gearcase. Use the side fill plug when 2 checking or changing oil. Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 63. Maintain the oil level (2) even with the bottom of the side fill hole. Refer to the Gearcase Specifications Chart on page 72 for recommended lubricants, capacities and torque specifications. See page 111 for the part numbers of Polaris products. Oil Check 1. Position the vehicle on a level surface. 2. Remove the side fill plug and view the oil level through the fill plug hole. 3. Add the recommended gearcase oil as needed. 4. Reinstall the fill plug. Torque to specification. Oil Change 1. Place a drain pan beneath the drain and remove the drain plug. Catch and discard used oil properly. 2. Clean and reinstall the drain plug with a new sealing washer. Torque to specification. 3. Remove the side fill plug and add the recommended fluid. 4. Check the oil level. Maintain the oil level at the bottom of the fill plug hole. 5. Reinstall the fill plug. Torque to specification. 6. Check for leaks. 75 MAINTENANCE Engine Cooling System To ensure that the coolant maintains its ability to protect the engine, Polaris recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water. Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. See page 111 for the part numbers of Polaris products. NOTE: Always follow the manufacturer’s mixing recommendations for the freeze protection required in your area. Any time the cooling system has been drained for maintenance or repair, replace the coolant. If the recovery bottle has run dry, the level in the radiator should be inspected. Add coolant as needed. WARNING Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the pressure cap. 76 MAINTENANCE Engine Cooling System Radiator Coolant Level 1. 2. 3. 4. 5. 6. Remove the bolts securing the front rack. See illustration. Remove the rack. Remove the pressure cap (1). Using a funnel, slowly add coolant through the radiator filler neck. Reinstall the pressure cap. Reinstall the front rack. NOTE: Use of a non-standard pressure cap will not allow the recovery system to function properly. Contact your dealer for the correct replacement part. 1 77 MAINTENANCE Engine Cooling System Coolant Level The recovery bottle (1) is located on the left side of the machine. To access the recovery bottle, remove the left side panel as outlined on page 82. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool). Add coolant as needed. 1 Cooling System Operation The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the recovery bottle, radiator filler neck, radiator pressure cap and connecting hose. As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator, past the pressure cap, and into the recovery bottle. As engine coolant temperature decreases, the contracting (cooled) coolant is drawn back up from the tank, past the pressure cap, and into the radiator. NOTE: 78 Some coolant level drop on new machines is normal, as the system is purging itself of trapped air. Observe coolant levels and maintain as recommended by adding coolant to the recovery bottle. Steering Assembly MAINTENANCE 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. Toe Alignment WARNING Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized Polaris dealer. Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8″ to 1/4″ (3-6 mm) toe out. 1. Set the handlebars in a straight-ahead position. NOTE: The steering frog can be used as an indicator of whether the handlebars are straight. The frog should always point straight back from the steering post. 2 2. Place stands (1) in front of the vehicle, perpendicular to the rear tires. See illustration. 3 3. Tie an elastic string around the stands, making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in front of the vehicle (2). 1 4. Measure the distance from the string to the rim at the front and rear of the front rim (3). Rear measurement should be 1/16″ - 1/8″ (1.5-3 mm) more than the front measurement. NOTE: If you discover improper alignment, see your Polaris dealer for service. 79 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. 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 keep brake fluid at an adequate level (see page 30). 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: 80 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. Brakes MAINTENANCE 2. Check the brake system for fluid leaks. 3. Check the brakes for excessive travel or spongy feel. 4. Check the friction pads for wear, damage and looseness. 5. Check the security and surface condition of the disc. NOTE: Pads should be changed when worn to 3/64″ (1 mm). Auxiliary Brake 3/64″ (1 mm) 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. 81 MAINTENANCE Side Panel Removal 1. Remove the seat. 2. Grasp the rear of the side panel near the rear cab. With a firm motion, pull the panel outward to disengage the side panel from the grommet. 3. Pull the panel downward and rearward to remove it from the ATV. 4. Reinstall the side panel by reversing the removal procedure. 3 1 2 3 Footwell Removal 2 1. Remove the four screws (1) on the bottom of the footwell. 2. Use a flat screwdriver or sidecutters to remove the plastic rivets (2) securing the footwell to the fenders. 3. Use a phillips screwdriver and wrench to remove the mudflap screws (3). 4. Remove the footwell. 3 1 82 Tires MAINTENANCE Refer to the specifications section beginning on page 112 for recommended tire type, size and pressure. WARNING Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Maintain proper tire pressure. Always use original equipment size and type when replacing tires. Make sure the wheels are installed properly. Always replace tires when the tread depth measures 1/8″ (3 mm) or less. Tire Tread Depth Always replace tires when tread depth is worn to 1/8″ (3 mm) or less. See illustration. 1/8I (3 mm) 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. Wheel Removal 1. 2. 3. 4. 5. Stop the engine. Place the transmission in PARK. Lock the parking brake. Loosen the wheel nuts slightly. Elevate the side of the vehicle by placing a suitable stand under the footrest frame. 6. Remove the wheel nuts. 7. Remove the wheel. 83 MAINTENANCE Tires Wheel Installation WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death. Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your Polaris dealer. 1. Place the transmission in PARK. 2. Lock the parking brake. 3. Place the wheel on the wheel hub with the valve stem toward the outside and the rotation arrows on the tire pointing toward forward rotation. 4. Install the wheel nuts and finger-tighten them. 5. Lower the vehicle to the ground. 6. Torque the wheel nuts to specification. 90 ft. lbs. (122 Nm) Cast Aluminum 27 ft. lbs. (37 Nm) Steel Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they’ve been loosened for maintenance service. 84 Item Specification Lug Nut 90 ft. lbs. (122 Nm) 2-Piece Flange Nut 27 ft. lbs. (37 Nm) Air Filter Service MAINTENANCE 1 1. Remove the seat, release the air box cover clips, and 2 remove the air box cover. 2. Loosen the clamp and remove the filter. 3. Remove the fabric type pre-filter (1) from the main filter (2). Wash the pre-filter in soapy water, then rinse and 3 let dry. 4. Reinstall the pre-filter over the main filter. (Replace the main filter if needed.) 5. Reinstall the filter into the air box and tighten the clamp. Do not over tighten the clamp, as filter damage could occur. 6. Reinstall the air box cover and the seat. Breather Filter/Hose 1. To access the breather filter (3), remove the left side panel as outlined on page 82. The breather filter is on the hose that runs between the engine and air box. 2. Remove the clamps and pull the filter out of the hoses. NOTE: It’s not necessary to remove the lower hose from the engine. 3. Inspect the filter for debris. Blow gently through the filter in the direction of the arrow to check for clogging. Replace if needed. 4. Check the hoses for cracks, deterioration, abrasion, or leaks. Replace as needed. 5. Reinstall the filter and secure the clamps. NOTE: The filter is effective with the arrow pointing in either direction. CAUTION Operation of your vehicle without a breather filter can cause engine damage. Always reinstall the breather filter after removing for service. 85 MAINTENANCE Lights When servicing a halogen lamp, don’t touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. WARNING Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation. Wash the headlights frequently to maintain lighting quality. Hot components can cause serious burns to skin. Allow lamps to cool before servicing. Headlight Lamp Replacement 1. Remove the two screws on the lower front corners of the headlight pod. 2. Remove the screw from the rear of the pod. 3. Lift the pod slightly while depressing the tabs at the rear of the pod. 4. Lift the pod cover and disconnect the speedometer harnesses from the speedometer. 5. Unplug the headlamp from the wiring harness. Be sure to pull on the connector, not on the wiring. 6. Turn the lamp counterclockwise to remove it. 7. Apply dielectric grease to the socket and install the new lamp. NOTE: Make sure the tab on the lamp locates properly in the housing. 8. Reassemble the pod. 86 Lights MAINTENANCE High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 25 ft. (7.6 m) 2″ (5 cm) 1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. Place the transmission in PARK. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. 3. Start the engine. Turn the headlight switch to high beam. 4. Observe the headlight aim on the wall. The most intense part of the headlight beam should be two inches (5 cm) below the mark on the wall. NOTE: Include rider weight on the seat when measuring. 5. The adjustment knob is located on the right side of the headlight pod. Adjust the beam to the desired position by turning the knob either clockwise or counterclockwise. 87 MAINTENANCE Lights Low Beam Adjustment 1 The low beam can be adjusted slightly upward or downward. 1. Loosen the headlamp mounting bolt (1). 2. Tilt the headlamp upward or downward. 3. Tighten the bolt. Headlight Housing Replacement 1. Remove the two screws on the lower front corners of the headlight pod. 2. Lift the pod slightly while depressing the tabs at the rear of the pod. 3. Lift the pod cover and disconnect the speedometer harnesses from the speedometer. 4. Unplug the headlamp from the wiring harness. 5. Use a small screwdriver to remove the o-rings from the headlight mounting tabs. 6. Pull the headlight housing up to release it from the locking tabs. 7. Lift the adjusting knob up to remove it from the locking tabs. 8. Carefully pull the assembly up and out of the pod. 9. Reverse the steps to install the new housing and reassemble the pod. NOTE: The distance from the headlamp parting line to the end of the adjustment knob stop is 5 1/8″ (13 cm). 10. Adjust the headlight aim by turning the adjusting knob. 5 1/8″ (13 cm) 88 MAINTENANCE Lights Lower Headlamp Removal / Installation 1. Turn the back of the headlight harness (1) in a clockwise direction. 2. Pull the harness assembly out from the headlight assembly. 3. Remove the headlamp and install 1 the new headlamp. 4. Install the new headlamp and harness assembly into the headlight assembly. Turn the headlight harness counterclockwise to secure. Taillight/Brakelight Lamp Replacement 1. Remove the taillight lens cover mounting screws (1). 2. Remove the lens cover (2) and gasket. 3. Remove the lamp (3). 4. Apply dielectric grease to the socket and install the new lamp. 5. Test the taillight/brakelight. 6. Reinstall the gasket and lens cover. 2 1 3 89 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 112 for the recommended spark plug type and gap for your vehicle. Spark Plug Torque Specification Plug Condition Torque New Spark Plug 9-11 ft. lbs. (12-15 Nm) Previously Installed Spark Plug 17-20 ft. lbs. (23-27 Nm) Spark Plug Inspection Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color. See page 91. 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, using the recommended spark plug. Torque to specification. 90 Spark Plugs MAINTENANCE Spark Plug Inspection Normal Spark Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be flaky and white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetion adjustments. Wet Fouled Spark Plug The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. General causes of fouling are excessive oil, use of non-recommended oil, improper use of the choke, or incorrect carburetion adjustments. 91 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 air box for any water and dry it if water is present. Filter replacement is required if water intrusion is evident. 3. Turn the fuel valve off. 4. Remove the spark plug. 5. Loosen the carburetor drain screw (1). 1 6. Turn the engine over several times using the electric start. 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: 92 If water has been ingested into the PVT, follow the procedure on page 96 for drying out the PVT. Recoil Housing Always drain the recoil housing (1) after operating the vehicle in wet conditions. Drain the housing before storing the vehicle. MAINTENANCE 1 NOTE: Make sure the housing is completely dry before reinstalling the drain screw. NOTE: Water will enter the recoil housing if the starter handle is disengaged from the rope guide when under water. 1. 2. 3. 4. 5. Stop the engine. Place the transmission in gear. Lock the parking brake. Remove the drain screw on the bottom of the recoil housing. Reinstall the drain screw. NOTE: Do not open the crankcase drain unless the engine has ingested water. On 4-cycle engines, some engine oil will be lost if the crankcase drain is opened. 93 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 PARK. 3. Start the engine. 2 4. Quickly squeeze and release the 1 throttle lever several times to purge carbon from the system. 5. If carbon comes out of the exhaust, cover or plug the exhaust outlet. Wear protective gloves. 6. Lightly tap on the exhaust pipe with a rubber mallet while repeating step 4. 7. If particles are still suspected to be in the muffler, elevate the rear of the vehicle one foot (30 cm) higher than the front. Block the wheels. 8. Place the transmission in PARK. Lock the parking brake. Repeat steps 4-6 until no more particles are expelled. 9. Stop the engine. Allow the arrestor to cool. 10. Reinstall the arrestor plug and remove the exhaust outlet cover or plug. 94 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. On Polaris ATVs, the approximate gear ratio difference between high and low range is 1:2.25. This difference in gearing affects the operation of the PVT, especially at speeds less than 7 MPH (11 KPH), due to the system’s dependence on engine speed. For example, when operating at a ground speed of 3 MPH (5 KPH) in low range, the engine speed would be around 3000 RPM. This is well above the engagement speed of 1200 - 1400 RPM. However, in high range at 3 MPH (5 KPH), the engine would be running at only 1500 RPM. Whenever operating this close to the engagement speed, the engine may be running at a speed too low to provide the pinch needed to prevent belt slip. Belt slip is responsible for creating the excessive heat that destroys belts and causes outer clutch covers to fail. By switching to low range while operating at low ground speeds, the air temperature in the clutch cover is reduced by almost 160 degrees. Reducing the temperature inside the clutch cover extends the life of the PVT components (belt, cover, etc.). When To Use Low Range and High Range Condition Range to Use Operating at speeds less than 7 MPH (11 km/h) Low Towing heavy loads Low Operating in rough terrain (swamps, mountains, etc.) Low Operating at speeds greater than 7 MPH (11 km/h) High 95 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. Replace the drain plug. 2. Start the engine and shift the transmission into neutral. Apply varying throttle for 10-15 seconds to expel the moisture and air-dry the belt and clutches. Do not hold the throttle wide open for more than 10 seconds. 3. Allow the engine RPM to settle to idle speed, then shift the transmission to the lowest available range. 4. Test for belt slippage. If the belt slips, repeat the process. 5. Take the vehicle to your dealer for service as soon as possible. 96 Battery MAINTENANCE 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. 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. 97 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. Remove the battery vent tube. 3. Disconnect the black (negative) battery cable first. 4. Disconnect the red (positive) battery cable last. 5. Lift the battery out of the ATV. Be careful not to tip the 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. 98 Battery MAINTENANCE Battery Installation 1. Ensure that the battery is fully charged. 2. Place the battery in the battery holder. 3. Install the battery 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. 5. 6. 7. 8. Coat the terminals with dielectric grease or petroleum jelly. Connect and tighten the red (positive) cable first. Connect and tighten the black (negative) cable last. Reinstall the battery cover. Secure the hold-down strap. Verify that cables are properly routed. NOTE: Cables should be safely tucked away at the front and rear of the battery. 99 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. Replenishing Battery Fluid A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. The fluid level should be kept between the upper and lower level marks (1). To refill use only distilled water. Tap water contains minerals that are harmful to a battery. 100 1 MAINTENANCE Camber and Caster The camber and caster are non-adjustable. Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster (1) either clockwise or counterclockwise to increase or decrease spring tension. NOTE: 1 Accessory springs are available through your Polaris dealer. Handlebars The handlebars can be adjusted for rider preference. WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in loss of control and possible serious personal injury or death. Follow the adjustment procedures exactly, or see your Polaris dealer for service. 1. Remove the upper headlight pod. 2. Loosen the four bolts (1). 3. Adjust the handlebar to the desired height. Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right. 4. Torque the front two bolts to 10-12 ft. lbs. (14-17 Nm), then torque the rear two bolts. A gap of up to 1/8” (3 mm) will remain at the rear bolts. 1 101 MAINTENANCE Carburetor Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for each 1000-foot (304.8 m) increase in elevation. Although this power cannot be regained, adjustments to the carburetor and drive system can be made to allow more efficient operation. Optional jets, available from your Polaris dealer, are required for operation above 6,000 feet and temperatures below +40 degrees F. (4 degrees C.) NOTE: Continuous operation of the engine without proper jetting when required can cause poor performance, overheating or PVT or engine damage. See your Polaris dealer for more information about jetting the ATV for conditions in your area. NOTE: Pilot screws are sealed with metal plugs and are serviceable only by Polaris dealers. Carburetor Idle If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted. 1. Start the engine and allow it to warm up for approximately five minutes. 2. Place the transmission in gear. 3. Lock the parking brake. 4. Turn the screw in (clockwise) to raise RPM. Turn the screw out (counterclockwise) to lower RPM. 102 1 Throttle Cable Freeplay MAINTENANCE Adjust throttle cable freeplay at the handlebar. 1. Locate the throttle cable adjuster at the handlebar. 2. Squeeze the end of the rubber boot and slide it far enough to expose the end of the inline cable adjuster. 3. Loosen the adjuster lock nut. 4. Rotate the boot to turn the adjuster until 1/16″ to 1/8″ (1.5--3 mm) of freeplay is achieved at the thumb lever. NOTE: While adjusting freeplay, be sure to flip the throttle lever back and forth. 5. Tighten the lock nut. 6. Squeeze the end of the rubber boot and slide it over the cable adjuster to its original position. 1 3 2 Accessories Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights. See your Polaris dealer. 103 MAINTENANCE Cleaning and Storage See page 111 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. 104 Cleaning and Storage MAINTENANCE 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 S Transmission seals S Brakes S Cab and body panels S Labels and decals 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 This vehicle has a factory-dulled finish. Do not polish this vehicle. 105 MAINTENANCE Cleaning and Storage Storage Tips CAUTION Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period. Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. See page 104. Stabilize the Fuel 1. Fill the fuel tank. 2. Polaris Carbon Clean is a fuel stabilizer and fuel system dryer. It cleans the fuel system, the combustion chamber and the exhaust ports. It also prevents bacterial growth and promotes better starting after the storage period. 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 70. 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. Breather Filter Inspect and clean or replace the breather filter. Recoil Housing Drain the recoil housing. See page 93. 106 Cleaning and Storage MAINTENANCE Storage Tips Fluid Levels Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 63. S Demand drive unit (front gearcase) S Rear gearcase (if equipped) S Transmission S Brake fluid (change every two years and any time the fluid looks dark or contaminated) S Coolant (test strength/fill) 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 Premium 4 Synthetic 0W40 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 106. 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. 107 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate. Follow lubrication guidelines in the Maintenance Section of the service or owner’s manual to completely grease and lubricate the entire vehicle with Polaris Premium All Season Grease. Battery Storage See page 100 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: 108 Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation. Cleaning and Storage MAINTENANCE 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. 109 MAINTENANCE Transporting the ATV Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place the transmission in PARK and lock the parking brake. 3. Turn the fuel valve off. Make sure the fuel caps, oil cap and seat are installed securely. 4. Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope. Do not attach tie straps to the front A-arm bolt pockets. 110 POLARIS PRODUCTS Part No. Description 2870791 2871281 2871844 Engine Lubricant Fogging Oil (12 oz. Aerosol) Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.) Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (gal.) 2873602 2873603 2871653 2872276 2870465 2876251 Gearcase / Transmission Lubricants Premium AGL Synthetic Gearcase Lubricant (qt.) Premium AGL Synthetic Gearcase Lubricant (gal.) Premium ATV Angle Drive Fluid (8 oz.) Premium ATV Angle Drive Fluid (2.5 gal.) Pump for Gallon Jug Demand Drive LT Premium Fluid (8 oz.) 2871312 2871322 2871423 2871460 2871515 2871551 2871329 2872073 2872348 Grease / Specialized Lubricants Grease Gun Kit, Premium All Season 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.) Dielectric Grease (Nyogelt) Chain Lube (6.25 oz. aerosol) Chain Lube (16 oz. aerosol) 2871323 2871534 Coolant 60/40 Coolant (gal.) 60/40 Coolant (qt.) 2872889 2871326 2870652 2872189 2872893 2871956 2871076 Additives / Miscellaneous Brake and Clutch Cleaner Carbon Clean Plus (12 oz.) Fuel Stabilizer (16 oz.) DOT4 Brake Fluid Engine Degreaser LOCTITE 565 Thread Sealant Polaris Battery Tender Charger 111 SPECIFICATIONS MV700 Gross Vehicle Weight Dry Weight Fuel Capacity, Front Tank Fuel Capacity, Rear Tank Towing Capacity Front Rack Capacity Rear Rack Capacity Hitch Tongue Capacity Winch Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Engine Oil Capacity Coolant Capacity Demand Drive Fluid Capacity Rear Gearcase Oil Capacity Engine Displacement Bore x Stroke Pilot Jet Main Jet Needle Jet Jet Needle Pilot Screw Alternator Output Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug / Gap Lubrication System Driving System Type 112 1900 lbs. (862 kg) 1170 lbs. (531 kg) 4.75 gal. (18 l) 4.0 gal. (15 l) 1500 lbs. (681 kg) 200 lbs. (91 kg) 400 lbs. (181 kg) 150 lbs. (68.1 kg) (Rear rack capacity and tongue weight not to exceed 400 lbs./181 kg) 2500 lbs. (1134 kg) 95 in. (241 cm) 48 in. (122 cm) 59 in. (150 cm) 50.75 in. (129 cm) 10.5 in. (26.7 cm) 71.5 in. (181.6 cm) unloaded 2 qts. (1.9 l) 3.2 qts. (3 l) 9 oz. (265 ml) 10 oz. (300 ml) EH068OLE017 683 80 x 68 45 157.5 P-6 (829) 4HB41-4 2 3/8 330 Watts @ 3000 rpm 9.78:1 Electric BST 34mm Mikuni CDI 13° BTDC @ 1200 RPM RC7YC / .035 in. (0.9 mm) Pressurized Wet Sump 4 Wheel Independent Shaft SPECIFICATIONS MV700 Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Drive Ratio - Front Drive Ratio - Final Tire Size/Pressure - Front Tire Size/Pressure - Rear Front Brake Rear Brake Parking Brake Front Suspension Rear Suspension Shock Adjustment Headlight Taillights Brake Light Instrument Cluster Side Lever (H/L/N/R/P) 7.49/1 5.11/1 3.05/1 3.82/1 3.10/1 25 x 8 - 12 / 5 psi (34.5 KPa) 25 x 8 - 12 / 5 psi (34.5 KPa) Single-Control Hydraulic Disc Single-Control Hydraulic Disc Hydraulic lock, all wheel MacPherson Strut with 8.2” (21 cm) of travel Progressive Rate with 8.5” (21.6 cm) of travel Rear Spring Preload Adjust 2 Single Beam on Grill (27 w) 8.26 w 26.9 w LCD 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) 162.5 157.5 1800-3700 (6000-12000) 155 150 Clutching Chart Altitude Meters (Feet) Shift Weight Drive Clutch Spring Driven Clutch Spring Helix* 0-1800 (0-6000) 20-56 PN 5631215 Blue/Green PN 7041157 White/Yellow PN 7041635 EBS 41-37 PN 5132751 1800-3700 (6000-12000) 20-54 PN 5631214 Blue/Green PN 7041157 White/Yellow PN 7041635 EBS 41-37 PN 5132751 *EBS models require no helix / spring adjustment 113 TROUBLESHOOTING Drive Belt and Cover Problems Possible Cause Solution Driving the ATV onto a pickup or tall trailer in high range. Shift transmission to low range during loading of the ATV to prevent belt burning. Starting out going up a steep incline. When starting out on an incline, use low range or dismount the ATV (after first applying the park brake) and perform the K-turn as described on page 57. Driving at low RPM or Drive at a higher speed or use low range more frequently. low ground speed (at 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 flexible and prevent belt burning. Slow and easy clutch engagement. Use the throttle quickly and effectively for efficient engagement. Towing/pushing at low RPM/low ground speed. Use low range only. Utility use/plowing snow, dirt, etc. 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. Contact your Polaris dealer for inspection of clutch components. Poor engine performance. Check for fouled plugs or foreign material in gas tank, fuel lines, or carburetor. Contact your dealer for service. 114 TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Engine Doesn’t Turn Over Possible Cause Solution Tripped circuit breaker Reset the breaker Low battery voltage Recharge battery to 12.5 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Engine Turns Over, Fails to Start Possible Cause Solution Out of fuel Refuel or switch tanks Clogged fuel valve or filter Inspect and clean or replace Water is present in fuel Drain the fuel system and refuel Fuel valve is turned off Turn the fuel valve on Old or non-recommended fuel Replace with new fuel Fouled or defective spark plug(s) Inspect plug(s), replace if necessary No spark to spark plug Inspect plug(s), verify stop switch is on Crankcase filled with water or fuel Immediately see your Polaris dealer Overuse of choke Inspect, clean and/or replace spark plugs Clogged fuel filter Replace the filter Low battery voltage Recharge battery to 12.5 VDC Mechanical failure See your Polaris dealer Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs 115 TROUBLESHOOTING Engine Backfires Possible Cause Solution Weak spark from spark plugs Inspect, clean and/or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non-recommended fuel Replace with new fuel Incorrectly installed spark plug wires See your Polaris dealer Incorrect ignition timing See your Polaris dealer Mechanical failure See your Polaris dealer Engine Runs Irregularly, Stalls or Misfires Possible Weak Spark Cause Solution Fouled or defective spark plugs Inspect, clean and/or replace spark plugs Worn or defective spark plug wires See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12.5 VDC Kinked or plugged fuel vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your Polaris dealer Electronic Throttle Control malfunction See your Polaris dealer Other mechanical failure See your Polaris dealer Possible Lean Fuel Mixture Cause Solution Low or contaminated fuel Add or change fuel, clean the fuel system Low octane fuel Replace with recommended fuel Clogged fuel filter Replace filter Incorrect jetting See your Polaris dealer Possible Rich Fuel Mixture Cause Solution Overuse of choke Inspect, clean and/or replace spark plugs Fuel is very high octane Replace with lower octane fuel Incorrect jetting See your Polaris dealer 116 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel or switch tanks Kinked or plugged fuel vent line Inspect and replace Water present in fuel Replace with new fuel Overuse of choke Inspect, clean and/or replace spark plugs Fouled or defective spark plugs Inspect, clean and/or replace spark plugs Worn or defective spark plug wires See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Low battery voltage Recharge battery to 12.5 VDC Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your Polaris dealer Electronic Throttle Control malfunction See your Polaris dealer Other mechanical failure See your Polaris dealer Overheated engine Clean radiator screen and core Clean engine exterior See your Polaris dealer Engine Overheating Possible Cause Solution Debris lodged in screen Remove and clean the screen. Pull on the top portion of the screen, then remove the lower portion. Plugged Radiator Use a garden hose to flush any debris from the radiator fins. NOTE: High pressure washers can deform the radiator fins and reduce cooling efficiency. 117 WARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty. This warranty begins on the date of purchase. This warranty is transferable to another consumer during the warranty period through a Polaris dealer. REGISTRATION At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will record the registration for warranty. No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement. If you have not signed the original registration and received the customer copy, please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS 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. 118 WARRANTY WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any ATV that has been altered structurally, modified, neglected, improperly maintained, used for racing, or used for purposes other than for which it was manufactured, or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, this 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 CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties, so the above limitations or exclusions may not apply to you if inconsistent with controlling state law. 119 WARRANTY ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you if inconsistent with controlling state law. HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris ATVs. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests that you use your original selling dealer; however, you may use any Polaris Servicing Dealer to perform warranty service. Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance they will contact the appropriate person at Polaris. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. If any of the above terms are void because of state or federal law, all other warranty terms will remain in effect. Engine Oil 1. Mixing oil brands or using non-recommended oil may cause engine damage. We recommend the use of Polaris engine oil for your ATV. 2. Damage resulting from the use of non-recommended lubricants may not be covered by warranty. SPARK ARRESTOR Polaris warrants that the spark arrestor in this vehicle will meet the efficiency requirements of 43 CFR 8343.1(c) for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with Polaris recommendations. 120 Exported Vehicles WARRANTY EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCATION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries. Dealers may not give authorization for export. You should consult an authorized dealer to determine this vehicle’s warranty or service bulletin coverage if you have any questions. This policy does not apply to vehicles registered to government officials or military personnel on assignment 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 perform the warranty repair. If You Move: If you move to another country, be sure to contact Polaris Customer Assistance and the customs department of the destination country before you move. Vehicles importation rules vary considerably from country to country. You may be required to present documentation of your move to Polaris Industries in order to continue your warranty coverage. You may also be required to obtain documentation from Polaris Industries in order to register your vehicle in your new country. 121 WARRANTY Exported Vehicles How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. Notice If your vehicle is registered outside of the country where it was purchased, and you have not followed the procedure set out above, your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind. (Vehicles registered to Government officials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty.) For questions call Polaris Customer Assistance: United States: 1-763-417-8650 Canada: 1-204-925-7100 122 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, or after 5000 km (3100 miles), whichever comes first. This emission--related warranty covers components whose failure would increase an engine’s emissions, including electronic controls, fuel injection, exhaust--gas recirculation, aftertreatment, or any other system utilized in this vehicle to control emissions. Replacing or repairing other components not covered by this emissions warranty or the standard warranty is the responsibility of the owner; including the parts, labor and other costs associated with recommended maintenance. 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 CONTRACT, NEGLIGENCE OR OTHER TORT OR OTHERWISE. ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply if it is inconsistent with the controlling state law. This limited warranty excludes failures not caused by a defect in material or workmanship. This limited warranty does not cover damage due to accidents, abuse or improper handling, maintenance or use. This limited warranty also does not cover any engine that has been structurally altered, or any engine that has been used in racing 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--763--417--8650. 123 MAINTENANCE RECORD DATE 124 MILES/KM TECHNICIAN SERVICE PERFORMED / COMMENTS MAINTENANCE RECORD DATE MILES/KM TECHNICIAN SERVICE PERFORMED / COMMENTS 125 MAINTENANCE RECORD DATE 126 MILES/KM TECHNICIAN SERVICE PERFORMED / COMMENTS INDEX A E Accessories . . . . . . . . . . . . . . . . . . 103 Age Restrictions . . . . . . . . . . . . . . . . 6 Air Filter Service . . . . . . . . . . . . . . . 85 All Wheel Drive . . . . . . . . . . . . . . . 37 Automatic Transmission . . . . . . . . . 34 Auxiliary Brake . . . . . . . . . . . . . . . 81 AWD . . . . . . . . . . . . . . . . . . . . . . . . 37 Electrical Switches . . . . . . . . . . . . . 27 Electromagnetic Interference . . . . . . 62 Emission Control Systems . . . . . . . 62 Engaging All-Wheel Drive . . . . . . . 37 Engine Break-in . . . . . . . . . . . . . . . 45 Engine Cooling System . . . . . . . 76-78 Engine Stop Switch . . . . . . . . . . . . 27 Equipment Modifications . . . . . . . . 10 Exhaust Emission Control System . 62 B Battery . . . . . . . . . . . . . . . . . . . 97-100 Battery Fluid . . . . . . . . . . . . . . . . . 100 Battery Installation . . . . . . . . . . . . . 99 Battery Removal . . . . . . . . . . . . . . . 98 Battery Storage . . . . . . . . . . . 100, 108 Belt Life . . . . . . . . . . . . . . . . . . . . . 34 Brake Fluid . . . . . . . . . . . . . . . . 30, 32 Brake Lever . . . . . . . . . . . . . . . . . . 29 Brake, Auxiliary . . . . . . . . . . . . . . . 32 Brakelight . . . . . . . . . . . . . . . . . . . . 89 Brakes . . . . . . . . . . . . . . . . . . . . . 80-81 Break-In Period . . . . . . . . . . . . . . . . 45 Breather Filter . . . . . . . . . . . . . . . . . 85 C Camber and Caster . . . . . . . . . . . . 101 Carburetor . . . . . . . . . . . . . . . . . . . 102 Choke . . . . . . . . . . . . . . . . . . . . . . . 33 Chrome Wheel Care . . . . . . . . . . . 109 Cleaning . . . . . . . . . . . . . . . . . 104-109 Clutching Chart . . . . . . . . . . . . . . . 113 Cold Weather Operation . . . . . . . . . 48 Coolant Level . . . . . . . . . . . . . . . . . 78 Cooling System . . . . . . . . . . . . . 76-78 Cooling System Operation . . . . . . . 78 Crankcase Emission Control System 62 D Demand Drive Fluid . . . . . . . . . . . . 73 Diagnostic Mode . . . . . . . . . . . . . 41-43 Drivetrain Break-in . . . . . . . . . . . . . 45 Driving Downhill . . . . . . . . . . . . . . 56 Driving in Reverse . . . . . . . . . . . . . 60 Driving on a Hillside . . . . . . . . . . . . 55 Driving on Slippery Surfaces . . . . . 53 Driving Procedures . . . . . . . . . . . . . 51 Driving Through Water . . . . . . . . . . 58 Driving Uphill . . . . . . . . . . . . . . . . 54 F Footwell Removal . . . . . . . . . . . . . . Front Gearcase Fluid . . . . . . . . . . . . Front Wheel Hub Tightening . . . . . Fuel Filter . . . . . . . . . . . . . . . . . . . . Fuel Requirements . . . . . . . . . . . . . Fuel Safety . . . . . . . . . . . . . . . . . . . Fuel Tanks . . . . . . . . . . . . . . . . . . . Fuel Valve . . . . . . . . . . . . . . . . . . . . 82 73 83 33 33 44 33 33 G Gear Selector . . . . . . . . . . . . . . . . . . 34 Gearcase Specification Chart . . . . . . 72 H Handlebars . . . . . . . . . . . . . . . . . . 101 Hauling Cargo . . . . . . . . . . . . . . . 49-50 Headlamp, Lower . . . . . . . . . . . . . . 89 Headlight Housing Replacement . . . 88 Headlight Lamp Replacement . . . . . 86 High Beam Adjustment . . . . . . . . . . 87 High Range . . . . . . . . . . . . . . . . . . . 95 Hour Meter . . . . . . . . . . . . . . . . . . . 40 I Idle RPM . . . . . . . . . . . . . . . . . . . 102 Ignition Switch . . . . . . . . . . . . . . . . 27 Infrared Light Switch . . . . . . . . . . . 27 Instrument Cluster . . . . . . . . . . . . 38-43 J Jetting Chart . . . . . . . . . . . . . . . . . 113 K K-Turn . . . . . . . . . . . . . . . . . . . . . . 57 127 INDEX L S Light Switches . . . . . . . . . . . . . . . . 29 Lights . . . . . . . . . . . . . . . . . . . . . 86-89 Locking the Parking Brake . . . . . . . 31 Low Beam Adjustment . . . . . . . . . . 88 Low Range . . . . . . . . . . . . . . . . . . . 95 Lower Headlamp . . . . . . . . . . . . . . 89 Lubrication Guide . . . . . . . . . . . . . . 68 Safe Riding Gear . . . . . . . . . . . . . . . 26 Safety Training . . . . . . . . . . . . . . . . . 6 Severe Use . . . . . . . . . . . . . . . . . . . 63 Side Panel Removal . . . . . . . . . . . . 82 Sidehilling . . . . . . . . . . . . . . . . . . . 55 Spark Arrestor . . . . . . . . . . . . . . . . . 94 Spark Plug Inspection . . . . . . . . . 90-91 Spark Plug Recommendations . . . . 90 Spark Plugs . . . . . . . . . . . . . . . . . 90-91 Specifications . . . . . . . . . . . . . 112-113 Starting the Engine . . . . . . . . . . . 47-48 Steering Assembly . . . . . . . . . . . . . 79 Stop Switch . . . . . . . . . . . . . . . . . . . 27 Storage . . . . . . . . . . . . . . . . . . 104-109 Storage Tips . . . . . . . . . . . . . . 106-108 Switches . . . . . . . . . . . . . . . . . . . . . 27 Switch, Light . . . . . . . . . . . . . . . . . 29 M Maintenance Chart . . . . . . . . . . . 63-67 Maintenance Record . . . . . . . . 124-126 Making Turns . . . . . . . . . . . . . . . . . 52 Master Cylinder . . . . . . . . . . . . . . . 30 Mode/Reverse Override Switch . . . 27 N Noise Emission Control System . . . 62 O Odometer . . . . . . . . . . . . . . . . . . . . 40 Oil Change . . . . . . . . . . . . . . . . . . . 71 Oil Check . . . . . . . . . . . . . . . . . . . . 70 Oil Filter Change . . . . . . . . . . . . . . 71 Operator Safety . . . . . . . . . . . . . . . 6-25 P Parking Brake . . . . . . . . . . . . . . . . . 31 Parking on an Incline . . . . . . . . . . . 61 Periodic Maintenance Chart . . . . 63-67 Polaris Products . . . . . . . . . . . . . . 111 Pre-Ride Inspection . . . . . . . . . . . . . 46 Premium 4 Synthetic Lubricant . . . . 69 PVT Break-in . . . . . . . . . . . . . . . . . 45 PVT Drying . . . . . . . . . . . . . . . . . . 96 PVT System . . . . . . . . . . . . . . . . 95-96 R Radiator Coolant Level . . . . . . . . . 77 Rear Gearcase Oil . . . . . . . . . . . . . . 75 Rear Spring . . . . . . . . . . . . . . . . . . 101 Recoil Housing . . . . . . . . . . . . . . . . 93 Recoil Starter . . . . . . . . . . . . . . . . . 35 Reverse Override Switch . . . . . . . . . 27 Rider Information Center . . . . . . 39-43 Run-Flat Tires . . . . . . . . . . . . . . . . . 36 128 T Tachometer . . . . . . . . . . . . . . . . . . . 40 Taillight . . . . . . . . . . . . . . . . . . . . . . 89 Throttle Cable Freeplay . . . . . . . . . 103 Throttle Lever . . . . . . . . . . . . . . . . . 28 Tires . . . . . . . . . . . . . . . . . . . . . . 83-84 Tires, Run-Flat . . . . . . . . . . . . . . . . 36 Toe Alignment . . . . . . . . . . . . . . . . 79 Transmission Oil . . . . . . . . . . . . . . . 74 Transporting the ATV . . . . . . . . . . 110 Trip Meter . . . . . . . . . . . . . . . . . . . . 40 Troubleshooting . . . . . . . . . . . 114-117 Turning Around on a Hill . . . . . . . . 57 V Vehicle Identification Numbers . . . . . 5 Vehicle Immersion . . . . . . . . . . . . . 92 W Warranty . . . . . . . . . . . . . . . . . 118-121 Washing the Vehicle . . . . . . . . . . . 104 Wheel Installation . . . . . . . . . . . . . . 84 Wheel Nut Torque Specifications . . 84 Wheel Removal . . . . . . . . . . . . . . . 83 Winch Switch . . . . . . . . . . . . . . . . . 27 Winches . . . . . . . . . . . . . . . . . . . . . 36
Source Exif Data:
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