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A card containing important ATV safety information should be attached to the

owner's manual on the next page. If you cannot locate this card, or if it has been

removed, please call 1-800-342-3764 for assistance.

WARNING

The engine exhaust from this

product contains chemicals known

to the State of California to cause

cancer, birth defects or other

reproductive harm.

Visit us at www.polarisindustries.com

POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc.

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 con-

tained within, whether whole or in part, is expressly prohibited.

Printed in U.S.A.

2008 Outlaw 525 IRS ATV Owner's Manual

P/N 9920972

Welcome

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

Polaris owners. We proudly produce an exciting line of utility and recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

•RANGER utility vehicles

• Victory motorcycles

Welcome

We believe Polaris sets a standard of excellence for all utility and recreational vehicles man-

ufactured 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 rec-

ommendations in this owner's manual. Your manual contains instructions for minor mainte-

nance, but information about major repairs is outlined in the Polaris Service Manual and

should be performed only by a Factory Certified Master Service Dealer (MSD) Technician.

Your Polaris dealer knows your vehicle best and is interested in your total satisfaction. Be

sure to return to your dealership for all of your service needs during, and after, the warranty

period.

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

through our online store at www.purepolaris.com. Have your accessories and clothing deliv-

ered right to your door!

Table of Contents

Know Your Vehicle . . . . . . . . . . . . 6

Safety Decals . . . . . . . . . . . . . . . . 8

Safety . . . . . . . . . . . . . . . . . . . . . 12

Features and Controls . . . . . . . . 50

Break-In Period. . . . . . . . . . . . . . 70

Pre-Ride Inspection . . . . . . . . . . 72

Operation . . . . . . . . . . . . . . . . . . 74

Emission Control Systems . . . . . 95

Maintenance . . . . . . . . . . . . . . . . 97

Specifications . . . . . . . . . . . . . . 186

Polaris Products . . . . . . . . . . . . 188

Troubleshooting. . . . . . . . . . . . . 190

Warranty . . . . . . . . . . . . . . . . . . 202

Maintenance Log . . . . . . . . . . . 211

Index . . . . . . . . . . . . . . . . . . . . . 215

Know Your Vehicle

The high performance engine in your vehicle requires routine service to maintain the highest

level of performance and reliability. Please read and follow the “Break-In Period” and

“Maintenance” sections of your Owner’s Manual carefully. Failure to perform the recom-

mended procedures at the service intervals specified in your owner’s manual will void war-

ranty coverage and decrease the performance and reliability of your vehicle.

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

ers, 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 pro-

cedures.

Vehicle Identification Numbers

Record your vehicle's identification numbers and key number in the spaces provided.

Remove the spare key and store it in a safe place. An ignition key can be duplicated only by

ordering a Polaris key blank (using your key number) and mating it with one of your existing

keys. The ignition switch must be replaced if all keys are lost.

Know Your Vehicle

Vehicle Identification Numbers

Vehicle Model Number: ____________________________________________________________________

Frame Vehicle Identification Number (1): ______________________________________________________

Engine Serial Number (2):__________________________________________________________________

Key Number (on the key): __________________________________________________________________

Safety Decals

Warning decals have been placed on the vehicle for your protection. Read and follow the

instructions on each decal carefully. If any of the decals shown in this manual differ from the

decals on your vehicle, always read and follow the instructions of the decals on the vehicle.

If any decal becomes

illegible or comes off,

contact your Polaris

dealer to purchase a

replacement.

Replacement safety

decals are provided by

Polaris at no charge.

The part number is

printed on the decal.

Age 16

Warning

General

Warning Sport ATV

Warning

Discretionary

Warning

Safety Decals

General Warning

WARNING

Improper ATV use can result in SEVERE

INJURY OR DEATH.

Always use an approved helmet and protective

gear. Never use on public roads. Never carry

passengers. Never use with drugs or alcohol.

NEVER operate:

• without proper training or instruction

• at speeds too fast for your skills or the

conditions

• on public roads - a collision can occur with

another vehicle

• with a passenger - passengers affect balance

and steering and increase risk of losing control

ALWAYS:

• use proper riding techniques to avoid vehicle

overturns on hills and rough terrain and in

turns

• avoid paved surfaces - pavement may

seriously affect handling and control.

LOCATE AND READ OWNER'S MANUAL.

FOLLOW ALL INSTRUCTIONS AND

WARNINGS.

IF OWNER'S MANUAL IS MISSING, CONTACT

A POLARIS DEALER FOR A REPLACEMENT.

7172560

Safety Decals

Age 16 Warning

WARNING

Operating this ATV if you are under the age of 16

increases your chance of severe injury or death.

NEVER operate this ATV if you are under age

16.

7172559

Sport ATV Warning

WARNING

This ATV may exceed the performance of other

ATVs you may have ridden in the past. This

category S (Sport) ATV is a high performance

vehicle for off-road use only, in sport type

recreation and competitive use by operators with

advanced skills and substantial experience.

7173837

Discretionary Warning

• Never operate this ATV on HILLS steeper than

25 degrees 25°. To prevent flipover on

hilly terrain, use throttle and brakes gradually.

• REVERSE operation can be dangerous even

at low speeds. Steering becomes difficult. To

prevent flipover, avoid sudden braking or

sharp turns.

• PARKING BRAKE may relax when used for

more than 5 minutes. When parking on

grades, leave ATV in gear.

7173837

Safety Decals

No Passenger Warning

WARNING

NEVER ride as a passenger.

Passengers can cause a loss of control, resulting

in SEVERE INJURY or DEATH.

7172566

Tire Pressure/Load Warning

WARNING

IMPROPER TIRE PRESSURE OR

OVERLOADING can cause loss of control,

resulting in SEVERE INJURY OR DEATH.

TIRE PRESSURE IN PSI (KPa): FRONT 4 (27.6)

REAR 4 (27.6)

MAXIMUM WEIGHT CAPACITY

215 LBS. (97.5 KG)

INCLUDES WEIGHT OF OPERATOR, CARGO

AND ACCESSORIES

Reduce speed and allow greater distance for

braking when carrying cargo. Overloading or

carrying tall, off-center, or unsecured loads will

increase your risk of losing control. For stability

on rough or hilly terrain, reduce speed and cargo.

Read Owner's Manual for more detailed loading

information.

7174881

Tire Pressure

Warning

Passenger

Warning

Safety

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.

Helmet

Wearing a helmet can prevent a severe head injury.

Whenever riding a Polaris vehicle, always wear a helmet

that meets or exceeds established safety standards.

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

Department of Transportation (DOT) label.

Approved helmets in Europe, Asia and Oceania bear the

ECE 22.05 label. The ECE mark consists of a circle sur-

rounding the letter E, followed by the distinguishing

number of the country which has granted approval. The

approval number and serial number will also be dis-

played on the label.

Helmet

Eye

Protection Gloves

Boots

Long Pants

Long

Sleeves

051039

0006.31

Safety

Riding Gear

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.

Gloves

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

Boots

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

Clothing

Always wear long sleeves and long pants to protect arms and legs. Riding pants with knee-

pads and a jersey with shoulder pads provide the best protection.

Safety

Operator Safety

Operator Restrictions/Age Restrictions

This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16

years of age. This category S (Sport) ATV is a high performance vehicle intended for off

road use only, for sport-type recreation and for competitive use by operators with advanced

skills and substantial experience.

WARNING

Failure to follow the warnings in this manual can result in severe injury or death.

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

other vehicles such as motorcycles and cars. A collision or rollover can occur quickly, even during

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

precautions.

Read and understand the owner's manual and all warnings before operating a Polaris ATV.

Safety

Operator Safety

Safety Training

ATV safety training is a top priority for

Polaris. When you purchased your new

ATV, your dealer instructed you on the

authorized ATV 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 age 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.

Follow the recommended maintenance

program outlined in your owner's manual.

This program is designed to ensure that all

critical components on your vehicle are

thoroughly inspected at specific intervals.

Safety

Operator Safety

The following signal words and symbols appear throughout this manual and on your vehicle.

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 injury.

WARNING

The safety alert warning indicates a potential hazard that may result in serious injury or death.

CAUTION

The safety alert caution indicates a potential hazard that may result in minor injury or damage to the

vehicle.

CAUTION

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

NOTE:

A note will alert you to important information or instructions.

Safety

Operator Safety

• Read this manual and all labels carefully.

Follow all operating procedures.

• Never operate an ATV without proper

instruction. Take a training course. Pur-

chasers of a new Polaris ATV and age eli-

gible 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.

• Never allow anyone under 16 years of

age to operate this ATV.

• Never permit a guest to operate the ATV

unless the guest has read this manual and

all product labels and has completed a

certified safety training course.

• Always avoid operating an ATV on any

paved surfaces, including sidewalks,

driveways, parking lots and streets.

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.

Safety

Operator Safety

• Never operate an ATV on a public street,

road or highway, including a dirt or

gravel road.

• 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.

• Never consume alcohol or drugs before

or while operating an ATV.

• Never operate at excessive speeds. Travel

at speeds appropriate for the terrain, visi-

bility and operating conditions, and your

experience.

• Never attempt jumps or other stunts.

• Never tow or pull an object behind the

ATV.

• Always inspect your ATV before each

use to make sure it's in safe operating

condition. Always follow the inspection

and maintenance procedures and sched-

ules outlined in your owner's manual.

• Always keep both hands on the handle-

bars and both feet on the footpegs of the

ATV during operation.

• Always travel slowly and use extra cau-

tion when operating on unfamiliar terrain.

Be alert to changing terrain conditions.

Safety

Operator Safety

• Never operate on excessively rough, slip-

pery or loose terrain.

• Always follow proper turning procedures

as described in this manual. Practice turn-

ing at low speeds before attempting to

turn at faster speeds. Do not turn at exces-

sive speeds.

• Always have the ATV inspected by an

authorized Polaris dealer if it's been

involved in an accident.

• Never operate the ATV on hills too steep

for the ATV or for your abilities. Practice

on smaller hills before attempting larger

hills.

• Always follow proper procedures for

climbing hills. Check the terrain carefully

before ascending a hill. Never climb hills

with excessively slippery or loose sur-

faces. Shift your weight uphill. Never

open the throttle suddenly or make sud-

den gear changes. Never go over the top

of a hill at high speed

• Always follow proper procedures for

going downhill and for braking on hills.

Check the terrain carefully before you

start down a hill. Shift your weight uphill.

Never go down a hill at high speed. Avoid

going down a hill at an angle, which

would cause the vehicle to lean sharply to

one side. Drive straight downhill.

Safety

Operator Safety

• Always follow proper procedures for

crossing the side of a hill. Avoid hills

with excessively slippery or loose sur-

faces. Shift your weight uphill. Never

attempt to turn the ATV around on any

hill until you've mastered (on level

ground) the turning technique outlined in

this manual. Avoid crossing the side of a

steep hill when possible.

• Always use proper procedures if you stall

or roll backwards while climbing a hill.

To avoid stalling, maintain a steady speed

when climbing a hill. If you stall or roll

backwards, follow the special 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.

Safety

Operator Safety

• 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 con-

trol.

• Always check for obstacles before oper-

ating 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.

• Avoid operating the ATV through deep or

fast-flowing water. If it's unavoidable,

travel slowly, balance your weight care-

fully, 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. Test the brakes after leaving

water. If necessary, apply them lightly

several times to allow friction to dry out

the pads.

Safety

Operator Safety

• 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.

• Always use the size and type of tires

specified for your ATV, and always main-

tain proper tire pressure.

• Never modify an ATV through improper

installation or use of accessories.

• Never exceed the stated load capacity for

your ATV.

• Always remove the ignition key when the

vehicle is not in use to prevent unautho-

rized use or accidental starting.

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.

Safety

Operator Safety

Equipment Modifications

We are concerned for the safety of our customers and for the general public. Therefore, we

strongly recommend that consumers do not install on a Polaris ATV any equipment that may

increase the speed or power of the vehicle, or make any other modifications to the vehicle for

these purposes. Any modifications to the original equipment of the vehicle create a substan-

tial safety hazard and increase the risk of bodily injury.

The warranty on your Polaris ATV is terminated if any equipment has been added to the

vehicle, or if any modifications have been made to the vehicle, that increase its speed or

power.

NOTE: The addition of certain accessories, including (but not limited to) mowers, blades, tires, spray-

ers, 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.

Safety

Operator Safety

WARNING

POTENTIAL HAZARD

Operating this ATV without proper instruction.

WHAT CAN HAPPEN

The risk of an accident is greatly increased if the operator does not

know how to operate the ATV properly in different situations and on

different types of terrain.

HOW TO AVOID THE HAZARD

Beginning and inexperienced operators should complete the ATV

RiderCoursesm offered by Polaris through the SVIA. They should then

regularly practice the skills learned in the course and the operating

techniques described in the Owner's Manual.

For more information about the ATV RiderCoursesm contact ATV Enrollment Express at (800) 887-

2887 or visit www.atvsafety.org.

Safety

Operator Safety

WARNING

POTENTIAL HAZARD

Failure to follow the skill and experience recommendations for this ATV.

WHAT CAN HAPPEN

Severe injury and/or death could occur if a beginner or inexperienced driver operates this ATV.

HOW TO AVOID THE HAZARD

Only operators with advanced skills and substantial experience should operate this ATV.

Safety

Operator Safety

WARNING

POTENTIAL HAZARD

Failure to follow the age recommendations for this ATV.

WHAT CAN HAPPEN

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

age recommendation operates this ATV.

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 this ATV. Only operators with advanced skills and

substantial experience should operate this ATV.

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.

Safety

Operator Safety

WARNING

POTENTIAL HAZARD

Operating an ATV on paved surfaces, including sidewalks,

paths, parking lots, and driveways.

WHAT CAN HAPPEN

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

surfaces may adversely affect the handling of the ATV and

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

HOW TO AVOID THE HAZARD

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

travel slowly and avoid sudden turns or stops.

Safety

Operator Safety

WARNING

POTENTIAL HAZARD

Operating this ATV on public streets, roads or highways.

WHAT CAN HAPPEN

The ATV could collide with another vehicle.

HOW TO AVOID THE HAZARD

Never operate the ATV on any public street, road or

highway, including dirt and gravel roads. In many states

it's illegal to operate ATVs on public streets, roads and

highways.

Safety

Operator Safety

WARNING

POTENTIAL HAZARD

Operating this ATV without wearing an approved helmet,

eye protection and protective clothing.

WHAT CAN HAPPEN

Operating an ATV without an approved helmet increases

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

an accident.

Operating without eye protection could result in an

accident and could increase the chance of a severe

injury in the event of an accident.

HOW TO AVOID THE HAZARD

Always wear an approved helmet that fits properly.

Always wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket, and

long pants.

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.

Safety

Operator Safety

WARNING

POTENTIAL HAZARD

Operating the ATV at excessive speeds.

WHAT CAN HAPPEN

Excessive speed increases the operator's

chance of losing control of the ATV, which can

result in an accident causing severe injury or

death.

HOW TO AVOID THE HAZARD

Always operate the ATV at a speed that's

proper for the terrain, visibility and operating

conditions, and your experience.

WARNING

POTENTIAL HAZARD

Failure to inspect the ATV before operating.

Failure to properly maintain the ATV.

WHAT CAN HAPPEN

Increases the possibility of an accident or

equipment damage.

HOW TO AVOID THE HAZARD

Always inspect your ATV each time you use it

to make sure the ATV is in safe operating

condition. Always follow the inspection and

maintenance procedures and schedules

described in the Owner's Manual.

Safety

Operator Safety

WARNING

POTENTIAL HAZARD

Attempting jumps and other stunts.

WHAT CAN HAPPEN

Attempting stunts increases the chance of an accident,

including an overturn.

HOW TO AVOID THE HAZARD

Never attempt jumps or other stunts. Avoid exhibition

driving.

Safety

Operator Safety

WARNING

POTENTIAL HAZARD

Towing or pulling an object behind the ATV.

WHAT CAN HAPPEN

A wagon, sled or other object towed behind an ATV

does not have brakes or steering. The object may

overturn or collide with other objects and cause

serious injuries.

HOW TO AVOID THE HAZARD

Never tow or pull an object behind the ATV.

Safety

Operator Safety

WARNING

POTENTIAL HAZARD

Failure to use extra caution when operating the ATV

on unfamiliar terrain.

WHAT CAN HAPPEN

Unfamiliar terrain may contain hidden rocks, bumps, or

holes that could cause loss of control or overturn.

HOW TO AVOID THE HAZARD

Travel slowly and use extra caution when operating on

unfamiliar terrain. Always be alert to changing terrain

conditions.

Safety

Operator Safety

WARNING

POTENTIAL HAZARD

Failure to use extra caution when operating on

excessively rough, slippery or loose terrain.

WHAT CAN HAPPEN

Operating on excessively rough, slippery or loose terrain

could cause loss of traction or loss of control, which

could result in an accident or overturn.

HOW TO AVOID THE HAZARD

Do not operate on excessively rough, slippery or loose

terrain until you've learned and practiced the skills

necessary to control the ATV on such terrain.

Always use extra caution on rough, slippery or loose

terrain.

Safety

Operator Safety

WARNING

POTENTIAL HAZARD

Turning improperly.

WHAT CAN HAPPEN

Improper turns could cause loss of control

and lead to a collision or overturn.

HOW TO AVOID THE HAZARD

Always follow proper procedures for turning

as described in the owner's manual. Practice

turning at slow speeds before attempting to

turn at faster speeds.Never turn at excessive

speed.

WARNING

POTENTIAL HAZARD

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.

Safety

Operator Safety

WARNING

POTENTIAL HAZARD

Removing hands from the handlebars or feet from the

footpegs 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 footpeg, it

could contact 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 footpegs of the ATV during

operation.

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 degrees 25°.>25°

Safety

Operator Safety

WARNING

POTENTIAL HAZARD

Climbing hills improperly.

WHAT CAN HAPPEN

Improper hill climbing could cause loss of control or overturn.

HOW TO AVOID THE HAZARD

Always follow proper procedures for climbing hills as described

in the Owner's Manual beginning on page 82.

Always check the terrain carefully before ascending any hill.

Never operate the ATV on hills steeper than 25 degrees 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.

Safety

Operator Safety

WARNING

POTENTIAL HAZARD

Traveling downhill improperly.

WHAT CAN HAPPEN

Improperly descending a hill could cause loss of control or

overturn.

HOW TO AVOID THE HAZARD

Always follow proper procedures for traveling down hills as

described in the owner's manual. NOTE: A special

technique is required when braking while traveling downhill.

See page 88. 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.

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 try 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 86. 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.

Safety

Operator Safety

WARNING

POTENTIAL HAZARD

Stalling, rolling backwards or improperly dismounting while

climbing a hill.

WHAT CAN HAPPEN

The vehicle could overturn.

HOW TO AVOID THE HAZARD

Maintain steady speed when climbing a hill

If all forward speed is lost: Keep your weight uphill. Apply the

front brakes gradually (right lever). When fully stopped, apply the

foot brake as well and then lock the parking brake.

If the ATV begins rolling backwards: Keep weight uphill. Never apply engine power. Never apply the

rear brake while rolling backwards. Apply the front brake slowly. When fully stopped, apply rear

brake as well, and then lock the parking brake. Dismount on uphill side, or to either side if pointed

straight uphill. Use the K-Turn to turn the ATV around and remount. See page 86.

Safety

Operator Safety

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 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.

Safety

Operator Safety

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.

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 described in the owner's manual

and on safety decals.

Safety

Operator Safety

WARNING

POTENTIAL HAZARD

Operating the ATV through deep or fast-flowing water.

WHAT CAN HAPPEN

Tires may float, causing loss of traction and loss of control, which could lead to an accident or

overturn.

HOW TO AVOID THE HAZARD

Avoid operating the ATV through deep or fast-flowing water. If it's unavoidable to enter water that

exceeds the recommended maximum depth (see page 90), 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.

Safety

Operator Safety

WARNING

POTENTIAL HAZARD

Overloading the ATV or carrying/towing cargo.

WHAT CAN HAPPEN

Overloading or carrying/towing cargo can

cause changes in vehicle handling, which

could lead to loss of control or an accident.

HOW TO AVOID THE HAZARD

Never haul cargo or tow a load with this ATV.

Never exceed the stated load capacity for this

ATV.

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.

Safety

Operator Safety

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.

WARNING

Operating a damaged ATV can result in an

accident with serious injury or death. After any

overturn or accident, have a qualified service

dealer inspect the entire machine for possible

damage, including (but not limited to) brakes,

throttle and steering systems.

Safety

Operator Safety

WARNING

Exhaust system components are very hot

during and after use of the vehicle. Hot

components can cause serious burns and fire.

Do not touch hot exhaust system

components. Always keep combustible

materials away from the exhaust system. Use

caution when traveling through tall grass,

especially dry grass.

WARNING

Leaving the keys in the ignition can lead to

unauthorized use of the vehicle resulting in

serious injury or death. Always remove the

ignition key when the vehicle is not in use.

Features and Controls

Start Button

Engine Stop Switch

Main Key Switch

Features and Controls

Main Key Switch

The main key switch must be in the RUN position to start the engine. See page 75 for starting

procedures.

Start Button

Press the start button to engage the starter. Always release the start button promptly when the

engine starts.

NOTE: If the starter fails to engage, replace the blown fuse or see your Polaris dealer.

Engine Stop Switch

Move the stop switch either left or right to the OFF

position to stop the engine quickly. The engine will

not start or run when the switch is off.

NOTE: Both the main switch and the engine stop switch

will shut off all electrical power to the vehicle,

including lights.

OFF OFFRUN

Features and Controls

Lights

Indicator Lights

An illuminated light in the indicator

window will alert you to the follow-

ing conditions.

• Hot engine

• Reverse gear is selected

• Neutral gear is selected

NOTE: If indicator lights fail to oper-

ate, check connections. See

your Polaris dealer for inspec-

tion of the capacitor and volt-

age regulator.

Reverse Neutral

Hot Engine

Features and Controls

Lights

Headlights

Use the light switch to turn the lights on and off

and to switch the lights from high beam to low

beam.

NOTE: The lights won't work unless the key is in the

ON position and the engine stop switch is 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. This vehicle 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.

Features and Controls

Clutch Lever

The hydraulic clutch lever is located on the left handlebar.

Squeeze the clutch lever toward the handlebar to disengage

the clutch. Disengage the clutch before shifting gears.

The clutch is self-adjusting, but lever position can be

changed to fit the operator’s hand. Turn the adjusting knob

counterclockwise to move the lever closer to the handle-

bar. Turn the adjusting knob clockwise to move the lever

away from the handlebar.

NOTE: The adjustment range is limited. Never apply excessive force to the knob. Always turn the

knob manually.

Always check the lever for smooth operation before riding. If the lever does not operate

smoothly, check the fluid level at the master cylinder. See page 55.

If the lever begins to feel unresponsive, bleed the clutch system as outlined on page 156.

Adjusting Knob

Features and Controls

Clutch Fluid

The clutch fluid master cylinder is located on the

left handlebar. Check the fluid level in the reservoir

before each ride. The level should be 4mm below

the upper edge of the reservoir. Do not overfill.

Polaris recommends the use of KTM Hydraulic

Clutch Oil. Do not use brake fluid. Do not mix

clutch fluid with any other hydraulic fluids. See

page 188 for the part numbers of Polaris products.

1. Position the vehicle on a level surface.

2. Turn the handlebar until the master cylinder is

in a horizontal position.

3. Remove the two cover screws, the cover and the

rubber boot.

4. Add the recommended fluid as needed.

5. Reinstall the cover, boot and screws securely.

Screws

Cover

Boot

Features and Controls

Throttle Lever

The throttle lever is located on the right handlebar.

Squeeze the lever toward the handlebar to increase

engine speed and vehicle movement. Engine speed

returns to idle when the lever is released. See page 159

for throttle adjustment procedures.

NOTE: Fuel is injected into the intake passage each time

throttle is applied. Do not squeeze the throttle lever

while starting the engine. Do not squeeze the throttle

lever when the engine is stopped.

WARNING

Operating with sticking or improperly operating throttle controls could cause an accident and lead to

severe injury or death. Never start or operate the vehicle with an 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

Features and Controls

Throttle Lever

This ATV is equipped with an 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 posi-

tion when the operator releases the throttle lever, the engine will stop.

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 mechanism.

Features and Controls

Foot Brake

The foot brake operates the rear brakes. The brake

pedal is located in front of the right-hand footpeg.

If the rear wheels slide while using the foot brake,

reduce brake pedal pressure to brake the wheels

without skidding.

Check the brake fluid level frequently for the foot

brake system. The reservoir is located under the

seat. Maintain the fluid level between the minimum

and maximum marks.

Check the rear brake light for proper operation

before each use of the vehicle. See page 132.

WARNING

Aggressively applying the foot brake when backing down a hill may cause rear tipover, which could

result in serious injury or death. Use caution when applying the foot brake. Do not aggressively

apply the foot brake when going forward. The rear wheels may skid and slide sideways, causing

loss of control and serious injury or death.

Footpeg

Foot Brake

Features and Controls

Hand Brake

The hand brake operates the front brakes. The

hand brake is located on the right handlebar.

Squeeze the brake lever toward the handlebar to

engage the front brakes. These brakes are

hydraulically activated disc type brakes.

Always test brake lever travel and master cylin-

der fluid level before riding. When squeezed, the

lever should feel firm. Any sponginess would

indicate a possible fluid leak or low master cylin-

der 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.

Hand Brake

Features and Controls

Master Cylinder/Brake Fluid

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. Do not overfill.

WARNING

An over-full master cylinder may cause brake drag or brake lock-up, which could result in serious

injury or death. Maintain brake fluid at the recommended level. Do not overfill.

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.

Features and Controls

Master Cylinder/Brake Fluid

Check the brake fluid in the master cylinder before each ride. If the fluid level is low add

DOT 4 brake fluid only. Do not overfill. See page 188 for the part numbers of Polaris prod-

ucts.

NOTE: When checking the fluid level, the master cylinder cover must be level.

Hand Brake Fluid Level

View the fluid level through the indicator window

on the side of the master cylinder. Maintain the

fluid level at or slightly above the mark near the

center of the sight glass. Do not overfill.

Foot Brake Fluid Level

The brake fluid reservoir is located under the seat.

Maintain the fluid level between the maximum

and minimum marks. Fluid Level Mark

Features and Controls

Parking Brake

1. Place the transmission in first

gear.

2. Squeeze and release the brake

lever two or three times, then

squeeze and hold.

3. Push the parking brake lock

down to engage the lock.

Release the brake lever.

4. To release the parking brake

lock, squeeze and release the

brake lever. The lock will auto-

matically disengage.

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.

Locked

Unlocked

Features and Controls

Parking Brake

Important Safeguards

• The parking brake may relax if left on for

a long period of time. Always block the

wheels to prevent rolling.

• Always block the wheels on the downhill

side of the ATV if leaving it parked on a

hill. Another option is to park the ATV in

a sidehill position.

• Never depend on the parking brake alone

if the ATV is parked on a hill. Always

block the wheels to prevent rolling.

• Place the transmission in first gear before

locking the parking brake.

Features and Controls

Manual Shift

Shift Pedal

The gear shift pedal is located in front of the left-hand footpeg. One

full stroke of the pedal shifts the transmission to the next gear in the

shifting sequence. The pedal automatically returns to a horizontal

position when released.

To upshift to a higher gear, place the toe of your boot under the gear

shift pedal and raise the pedal one full stroke.

To downshift, place your foot on the gear shift pedal and depress the

pedal one full stroke. See page 65.

NOTE: To shift into reverse, see page 66.

WARNING

Shifting without releasing the throttle and disengaging the clutch

could cause loss of control or vehicle overturn. Always release the

throttle and fully squeeze the clutch lever while shifting gears.

Upshift

Downshift

Features and Controls

Manual Shift

Shifting Gears

NOTE: Always allow a cold engine to warm up before shifting gears.

1. When starting from a stopped position, place the transmission in neutral.

2. Squeeze and hold the brake lever.

NOTE: Do not squeeze the throttle lever.

3. Squeeze the clutch lever to disengage the clutch.

4. Depress the gear shift pedal one full stroke to shift into first gear.

5. Release the brake lever.

6. Gradually squeeze the throttle lever while slowly releasing the clutch lever.

7. As engine speed (RPM) increases in first gear, simultaneously release the throttle, disen-

gage the clutch and shift to second gear by raising the gear shift pedal one full stroke.

Repeat this procedure to progressively upshift to additional gears.

8. Use the same procedure to downshift.

Features and Controls

Manual Shift

Reverse Lock-Out Switch

The reverse lock-out switch prevents the

operator from shifting into reverse

unintentionally.

1. Place the transmission in first gear. See

page 64.

2. Push the lock-out lever forward toward

the handlebar to unlock the transmission.

3. Shift down into reverse gear.

NOTE: The lock will automatically re-engage

when the transmission is shifted out of

reverse gear.

Lock-Out Lever

Features and Controls

Manual Shift

Deceleration

To slow or stop the vehicle, release the throttle lever and apply the brakes smoothly and

evenly. As the vehicle slows and engine RPM decreases, disengage the clutch and shift to a

lower gear.

NOTE: Be sure the engine RPM has sufficiently decreased before shifting to a lower gear.

WARNING

Improper use of the brakes, or shifting when the engine RPM is too high can cause the tires to lose

traction or stop rotating, which could lead to loss of control, accident, and injury. It could also cause

engine or drive train damage.

Make sure the engine RPM has sufficiently decreased before shifting to a lower gear.

Features and Controls

Choke

The choke assists in starting a cold engine. The choke

knob is located on the left side of the carburetor. Refer

to the engine starting procedure on page 75 for correct

choke and throttle settings during starting.

Fuel Tank

The fuel tank filler cap is located directly below the

handlebar. Polaris recommends the use of 91 octane or

higher fuel. Do not use E-85 fuel.

Fuel Filter

The fuel valve has an internal fuel filter. Do not attempt

to clean the fuel filter. See your Polaris dealer for ser-

vice if you suspect the fuel filter is plugged.

Choke Knob

Features and Controls

Fuel Valve

The fuel valve is located on the left side of the ATV. It

has three positions:

OFF: For vehicle storage and when transporting.

ON: For normal operation.

RES: For reserve supply if main supply is exhausted.

NOTE: There's about a 5 to 8 mile (8 to 13 km) range on

reserve gas. Always refill the gas tank as soon as

possible after using the main supply.

Always return the valve to the ON position after refueling.

Break-In Period

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

and longer life for both. The break-in period for your new Polaris ATV is the first three hours

of operation, or the time it takes to use 5-6 gallons (20 liters) of fuel. Do not allow engine

speed to exceed 7000 RPM during the break-in period. Follow the break-in period with an

additional 12 hours of cautious operation, with engine speed below 75% of capacity.

No single action on your part is as important as following the procedures for a proper break-

in. Perform the following break-in and maintenance procedures carefully.

CAUTION

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

parts. Do not allow engine speed to exceed 7000 RPM during the first three hours of use.

Mixing brands or using a non-recommended oil may cause serious engine damage. Always use the

recommended oil. Never substitute or mix oil brands.

Break-In Period

1. Fill the fuel tank with gasoline. See page 74.

2. Check the oil level. Add the recommended oil as needed to maintain the oil level in the

proper range. See page 109.

3. Allow the engine sufficient time to warm up before operating.

4. Drive slowly at first. Select an open area that allows room to familiarize yourself with

vehicle operation and handling.

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

6. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride

inspection checklist. See page 72.

7. At the end of the break-in period (3 hours), change the engine oil and the long and short

oil filters. See page 110. Clean the oil screen and drain plug magnet.

CAUTION

Failure to perform the recommended break-in maintenance procedures can result in serious engine

damage. Change the oil and filters after the first three hours of 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 Page

Brake systems / lever travel Ensure proper operation 58-63

160-161

Brake fluid Ensure proper level 60

Clutch lever Check for proper operation and adjustment 54

Clutch fluid Ensure proper level 55

Suspension, front and rear Inspect, lubricate if necessary 104

Steering Check for free operation/loose components --

Frame nuts, bolts, fasteners Inspect, ensure tightness --

Fuel and oil Ensure proper levels 68, 109

Pre-Ride Inspection

Pre-Ride Checklist Page

Coolant (if applicable) Ensure proper level 119

Coolant hoses (if applicable) Inspect for leaks --

Throttle Ensure smooth operation 56

Indicator lights / switches Ensure operation 52, 53

Engine stop switch Ensure proper operation 51

Air filter Inspect, clean, replace as needed 122

Air box sediment tubes Drain deposits when visible --

Headlamp Check operation, apply Polaris dielectric grease to

the socket when the lamp is replaced 129

Brake light / tail lamp Check operation, adjust brake light switch 132

Riding gear Wear helmet, goggles, protective clothing 12

A-arm ball joints Check freeplay. If the tire moves excessively, do not

operate. See your Polaris dealer. --

Rear shaft assembly Check boots for tears, punctures and grease leaks 154

Operation

Fuel System

WARNING

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

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

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

where gasoline is stored.

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

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

clothing.

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

can cause loss of consciousness or death in a short time.

• Turn the fuel valve off whenever the vehicle is stored or parked. See page 69.

• Make sure the vent line is in good condition and is routed properly.

Operation

Starting the Engine

The engine can be started when the transmission is in neutral, or while in gear if the clutch is

disengaged. If starting a warm engine, do not use the choke.

NOTE: Fuel is injected into the intake passage each time the throttle lever is depressed. Do not

depress the throttle lever while starting the engine. Do not depress the throttle lever when the

engine is stopped.

WARNING

Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness

resulting in severe injury or death. Never run an engine in an enclosed area.

CAUTION

Operating the ATV immediately after starting could cause engine damage. Allow the engine to warm

up for several minutes before operating.

Operation

Starting the Engine

1. Shift the transmission to neutral.

2. Lock the parking brake.

3. Turn the fuel valve on.

4. Sit on the vehicle.

5. Disengage the clutch.

6. If the engine is cold, pull the

choke knob out until it stops. Do

not use the choke if starting a

warm engine.

7. Move the engine stop switch to

the RUN position.

8. Turn the ignition key to ON.

Choke Knob

Full On

Off

Operation

Starting the Engine

NOTE: If starting the engine while in gear, apply the hand brake and squeeze the clutch lever fully to

disengage the clutch. If starting the engine while in neutral, the neutral indicator light should

be on. If it isn't, disengage the clutch and shift the foot pedal to find neutral. See page 64.

9. Press the start button to start the engine. Activate the starter for a maximum of five sec-

onds. Release the start button immediately when the engine starts.

NOTE: Fuel is injected into the intake passage each time the throttle lever is depressed. Do not

depress the throttle lever while starting the engine. Do not depress the throttle lever when the

engine is stopped.

NOTE: Excessive engagement may result in starter damage.

10. If the engine does not start, wait five seconds after releasing the start button, then acti-

vate the starter for another five seconds. Repeat until the engine starts.

NOTE: If the engine does not start, review the engine troubleshooting information beginning on page

190. If all conditions are favorable and the engine still does not start, see your Polaris dealer

for service.

11. Push the choke knob completely in.

12. Vary engine speed slightly with the throttle to aid in warm-up.

Operation

Driving Procedure

1. Sit upright with both feet on the footpegs and

both hands on the handlebars.

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

3. Shift the transmission into gear. See page 64.

4. Check your surroundings and determine your

path of travel.

5. Release the parking brake.

6. Slowly depress the throttle with your right

thumb while slowly releasing the clutch lever to

begin driving.

7. Drive slowly. Practice maneuvering and using

the throttle, clutch and brakes on level surfaces.

Operation

Making Turns

Practice making turns at slow speeds before attempting to turn at faster speeds.

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

both rear wheels equally at all times. The wheel on the outside

of the turn travels a greater distance than the inside wheel

when turning, and the inside tire slips 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 footpeg. 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.

WARNING

Turning at sharp angles or at excessive speeds can result in vehicle overturn and lead to serious

injury or death. Avoid turning at sharp angles. Never turn at high speeds.

Operation

Driving on Slippery Surfaces

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, especially when downshifting.

Operation

Driving on Slippery Surfaces

Whenever riding on slippery surfaces such as

wet trails or loose gravel, or during freezing

weather, follow these precautions:

1. Slow down when entering slippery areas.

2. Maintain a high level of alertness, reading

the trail and avoiding quick, sharp turns,

which can cause skids.

3. Correct a skid by turning the handlebars in

the direction of the skid and shifting your

body weight forward.

Operation

Driving Uphill

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.

Operation

Driving Uphill

Whenever traveling uphill, follow these

precautions:

1. Always travel straight uphill.

2. Avoid steep hills (25° maximum).

3. Keep both feet on the footpegs.

4. Transfer your weight forward.

5. Proceed at a steady rate of speed and

throttle opening.

6. Remain alert and be prepared to take

emergency action. This may include

quick dismounting of the vehicle. 25° Maximum

Operation

Driving Across Hillsides

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.

Operation

Driving Across Hillsides

If you enter into a situation where sidehilling is unavoidable, follow these precautions:

1. Slow down.

2. Lean into the hill, transferring your

upper body weight uphill while keep-

ing your feet on the footpegs.

3. Steer slightly into the hill to maintain

direction.

NOTE: If the vehicle begins to tip, quickly

turn the front wheels downhill, if

possible, or dismount on the uphill

side immediately!

Operation

Turning Around on a Hill

If the vehicle stalls while climbing a hill, never back it down the hill! One maneuver that can

be used when it's necessary to turn around while climbing a hill is the K-turn:

1. Keep your body weight uphill.

2. Pull in the clutch lever and apply the front and rear brakes.

3. When completely stopped, shut off the engine. Leaving the transmission in gear, release

the clutch lever and lock the parking brake.

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

straight uphill.

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

WARNING

Improper hill climbing procedures could cause loss of control or overturn and result in serious injury

or death. Avoid climbing steep hills (25° maximum). Use extreme caution when operating on hills,

and follow proper operating procedures outlined in the owner's manual.

Operation

Turning Around on a Hill

6. Reach across the handlebar and apply the front

brakes to unlock the parking brake.

7. With the front brakes applied, pull in the

clutch lever. Use the brakes to slowly allow

the vehicle to roll around to your right until it's

pointing across the hill or slightly downward.

8. With the front brakes still applied, release the

clutch lever and lock the parking brake.

Remount from the uphill side, keeping body

weight uphill.

9. Pull in the clutch lever, shift into neutral and

restart the engine.

10. Release the parking brake and slowly release the clutch lever, allowing the ATV to pro-

ceed slowly. Stay in first gear, using the brakes for additional speed control if necessary,

until more level ground is reached. Do not apply the brakes abruptly when driving down-

hill.

8 ft. (2.4 m)

Operation

Driving Downhill

Whenever descending a hill, follow these

precautions:

1. Drive directly downhill.

2. Transfer your weight to the rear of the

vehicle.

3. Slow down.

4. Shift to the lowest gear possible while

maintaining a safe speed.

5. Apply the foot brake slightly to aid in

slowing.

WARNING

Excessive speed can cause loss of control and lead to serious injury or death. Always operate

slowly when traveling downhill.

Operation

Parking on a Hill or Incline

Avoid parking on a hill or incline if pos-

sible. If it's unavoidable, follow these

precautions:

1. Turn the engine off.

2. Place the transmission in first gear.

3. Lock the parking brake.

4. Always block the rear wheels on the

downhill side. See illustration.

5. Turn the fuel valve off.

Operation

Driving Through Water

Your ATV can operate through water with a

maximum recommended depth equal to the

level of the footpegs. Follow these proce-

dures when operating through water:

1. Determine water depths and current

before crossing.

2. Choose a crossing where both banks

have gradual inclines.

3. Proceed slowly, avoiding rocks and

obstacles if possible.

4. After driving through water, dry the

brakes by applying light pressure to the

lever (while moving) until braking action

is normal. If you do not perform this pro-

cedure, your brakes may be ineffective.

Maximum Depth

Operation

Driving Through Water

Avoid operating your ATV through deep or fast flowing water. If the ATV is operated in

deeper water than recommended, it's critical to have it serviced as outlined in the mainte-

nance chart beginning on page 97. Engine oil and all grease fittings need special attention.

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 142. Have the vehicle serviced by your dealer at the first

opportunity.

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 footpeg level, take it to your dealer for service before starting the

engine.

Operation

Driving in Reverse

Follow these guidelines when operating in

reverse:

1. Back slowly.

2. Apply the brakes lightly for stopping.

3. Avoid turning at sharp angles.

4. Always avoid backing downhill.

5. Never open the throttle suddenly while

backing.

6. Always look left, right and behind the

ATV before backing.

Operation

Driving in Reverse

This Polaris ATV is equipped with a reverse speed limiter. Do not operate at full throttle. Use

just enough throttle to maintain a desired speed.

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. Follow the reverse operation

procedures outlined in this manual.

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.

Operation

Driving Over Obstacles

Be alert! Look ahead and learn to read the ter-

rain you're traveling on. Be constantly alert

for hazards such as logs, rocks and low hang-

ing 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.

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 require-

ments.

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 arres-

tor be installed and functional when the vehicle is operated on public lands.

Operation of off-road vehicles on public lands in the U.S.A. is regulated by 43 CFR

8343.1(c). Violations are subject to monetary penalties. Federal regulations can be viewed

online at www.gpoaccess.gov/ecfr/.

Electromagnetic Interference

This spark ignition system complies with Canadian ICES-002.

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

Emission Control Systems

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 main-

tained at Polaris specifications to achieve optimal performance.

Engine idle speed is the only adjustment Polaris recommends that the operator perform. Any

other adjustments should be performed by an authorized Polaris dealer.

The compliance label is located on a frame tube to the left side of the frame, behind the radi-

ator.

Maintenance

Periodic Maintenance Chart

The high performance engine in your vehicle requires routine service to maintain the highest

level of performance and reliability. Please read and follow the “Break-In Period” and

“Maintenance” sections of your Owner’s Manual carefully.

Failure to perform the recommended procedures at the service intervals specified in your

owner’s manual will void warranty coverage and decrease the performance and reliability of

your vehicle.

Recommended service intervals are based on average riding conditions. Vehicles subjected

to severe use must be inspected and serviced more frequently.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation

Maintenance

Periodic Maintenance Chart

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

need for replacement parts, use genuine Polaris parts available from your Polaris dealer.

Record maintenance and service in the Maintenance Log beginning on page 211.

NOTE: Service and adjustments are critical. If you're unable to perform the required service and

adjustment procedures, have a qualified dealer perform these operations.

Maintenance

Periodic Maintenance Chart

Maintenance Chart Key

X Perform these operations more often under severe use.

EEmission-related service (Failure to conduct this maintenance will not void the

emissions warranty but may affect emissions.)

QHave an authorized Polaris dealer perform these services.

zUse Polaris Premium All Season Grease or grease conforming to NLGI No. 2.

WARNING

Improperly performing the procedures marked with a Q could result in component failure and lead to

serious injury or death. Have an authorized Polaris dealer perform these services.

100

Maintenance

Periodic Maintenance Chart

Item Maintenance Interval

(whichever comes first) Remarks See

Page

Hours Calendar Fuel Used

Brake systems/brake fluid --

Pre-ride

Check each day before operating

the vehicle. Make adjustments as

needed. See the Pre-Ride

Checklist.

Tires -- --

Wheels/lug nuts -- --

Frame fasteners -- --

Coolant -- --

Fuel -- --

Engine oil -- --

Transmission oil -- --

Throttle -- --

Clutch system/clutch fluid -- --

Lights -- --

Engine stop switch -- --

Steering -- --

101

Maintenance

Periodic Maintenance Chart

XPerform these procedures more often for vehicles subjected to severe use

EEmission-Related Service

QHave an authorized Polaris dealer perform these services

zUse Polaris Premium All Season Grease

Item Maintenance Interval

(whichever comes first) Remarks See

Page

Hours Calendar Fuel Used

in gallons (liters)

Air box sediment tubes -- Pre-ride -- Check each day before operating

the vehicle. Make adjustments as

needed. See the Pre-Ride Check-

list.

Headlamp -- --

Tail lamp/brake lamp -- --

A-arm ball joint -- --

Rear shaft assembly -- --

Boots -- Post-ride -- Burp boots if bulging/ballooned 155

Oil and filter change

3 Break-in 5 (20)

Change the oil and filters 110

Oil screen/drain plug Clean screen and plug magnet 112

Idle speed Check idle speed setting 124

Engine mounting bolts Check torque --

EValve clearance Check; adjust --

102

Maintenance

Periodic Maintenance Chart

Item Maintenance Interval

(whichever comes first) Remarks See

Page

Hours Calendar Fuel Used

in gallons (liters)

Brake pad wear 10 Monthly -- Inspect regularly 161

Rear sprocket bolts 10 Monthly -- Check torque 166

Battery 10 Monthly -- Check terminals; clean; test 145

XEAir filter 15 Weekly -- Inspect; clean; replace as needed 122

XOil and filter change 15 6 M 26 (100) Perform initial oil change after first

3 hours of operation.

110

XOil screen/drain plug 15 6 M 26 (100) Clean screen and plug magnet 112

Idle speed 15 6 M 26 (100) Check; adjust as needed 124

Engine mounting bolts 15 6 M 26 (100) Check torque --

Shift lever bolt 15 6 M 26 (100) Check torque --

EValve clearance 15 6 M 26 (100) Check; adjust --

Clutches 30 6 M 52 (200) Check discs for wear --

ESpark plug 30 6 M 52 (200) Replace 136

103

Maintenance

Periodic Maintenance Chart

XPerform these procedures more often for vehicles subjected to severe use

EEmission-Related Service

QHave an authorized Polaris dealer perform these services

zUse Polaris Premium All Season Grease

Item Maintenance Interval

(whichever comes first) Remarks See

Page

Hours Calendar Fuel Used

in gallons (liters)

XzGeneral lubrication 45 3 M 78 (300) Lubricate all fittings, pivots,

cables, etc.

Carburetor float bowl 45 6 M 78 (300) Drain bowl periodically and prior

to storage

125

QEThrottle cable/ETC switch 45 6 M 78 (300) Inspect; adjust; replace as needed 159

XDrive chain(s) 45 6 M 78 (300) Inspect daily; adjust; lubricate if

needed

164

XQBrake pad replacement 45 6 M 78 (300) See your Polaris dealer --

Coolant strength 45 6 M 78 (300) Inspect strength seasonally 118

104

Maintenance

Periodic Maintenance Chart

Item Maintenance Interval

(whichever comes first) Remarks

Hours Calendar Fuel Used

in gallons (liters)

XzUpper steering post (1) 45 6 M -- Inspect; tighten fasteners; grease after

washing ATV/driving in water

XzFront A-Arms (2) 45 6 M -- Inspect; tighten fasteners; grease

(also after washing ATV or driving

in water)

XzStabilizer Bar (3) 45 6 M -- Grease

XzRear Control Arm Needle

Bearings (4)

90 12 M -- Disassemble; clean; inspect bearings/

seals; grease; reassemble

105

Maintenance

Periodic Maintenance Chart

XPerform these procedures more often for vehicles subjected to severe use

EEmission-Related Service

QHave an authorized Polaris dealer perform these services

zUse Polaris Premium All Season Grease

Item Maintenance Interval

(whichever comes first) Remarks See

Page

Hours Calendar Fuel Used

in gallons (liters)

Clutch springs 60 12 M 104 (400) Check spring length (see dealer) --

Cam chain tensioner 60 12 M 104 (400) Check ratchet teeth for wear --

Coolant system 90 12 M 156 (600) Pressure test system annually --

XCooling system hoses 90 12 M 156 (600) Inspect --

Radiator 90 12 M 156 (600) Inspect; clean external surface;

change coolant every 2 years

QEFuel system 90 12 M 156 (600) Check for leaks at tank cap, lines,

fuel valve, filter, carburetor;

replace lines every two years

ECylinder and piston 90 -- 156 (600) Inspect; measure; replace as

needed

Piston pin circlip groove 90 -- 156 (600) Visual inspection for wear --

106

Maintenance

Periodic Maintenance Chart

Item Maintenance Interval

(whichever comes first) Remarks

Hours Calendar Fuel Used

in gallons (liters)

ECompression ring 90 -- 156 (600) See your dealer or refer to the Dealer

Service Manual; measure ring gap and

replace if at or below service limit

EOil scraper ring 90 -- 156 (600)

Camshaft 90 -- 156 (600) Visual inspection for wear

Valve spring cap 90 -- 156 (600) Visual inspection for wear

ECamshaft bearings 90 -- 156 (600) Replace

EValve springs 90 -- 156 (600) See your dealer or refer to the Dealer

Service Manual; perform measurements;

replace as needed

EValve seats/guides 90 -- 156 (600)

ERocker arm rollers 90 -- 156 (600)

ETiming chain 90 -- 156 (600) Measure elongation; replace as needed

Cam chain tensioner 90 -- 156 (600) Check ratchet teeth for wear

EBearings (connecting rod,

balance shaft, crankshaft

main)

90 -- 156 (600) Replace

Crankshaft run-out 90 -- 156 (600) Measure; adjust as needed

107

Maintenance

Periodic Maintenance Chart

XPerform these procedures more often for vehicles subjected to severe use

EEmission-Related Service

QHave an authorized Polaris dealer perform these services

zUse Polaris Premium All Season Grease

Item Maintenance Interval

(whichever comes first) Remarks See

Page

Hours Calendar Fuel Used

in gallons (liters)

Oil pressure valve 90 -- 156 (600) Measure spring; replace as needed

Transmission 90 -- 156 (600) Check entire transmission/bearings for

wear; replace as needed

QEIgnition Timing -- 12 M -- Inspect; adjust as needed

Clutch fluid 90 12 M -- Bleed as needed; change yearly 156

QEJet needle/needle jet 180 24 M -- Replace

QBrake fluid 180 24 M -- Replace

Spark arrestor 300 36 M -- Clean out 139

QFront/rear wheel bearings 300 36 M -- Inspect; replace as needed

QToe adjustment As required Inspect periodically; adjust when

parts are replaced

162

Headlight aim As required Adjust as needed 128

108

Maintenance

Engine Oil Recommendations

Always check and change the engine oil at the intervals outlined in the Periodic Maintenance

Chart beginning on page 97. Polaris recommends the use of Polaris PS-4 PLUS Performance

Synthetic 2W-50 4-cycle oil or a similar oil designed for use in 4-stroke manual clutch ATV

and motorcycle applications. See page 188 for the part numbers of Polaris products.

NOTE: Do not use Polaris PS-4 Performance Synthetic Oil. Always use 2W-50.

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

accumulation of contaminates such as water or excess fuel in the bottom of the crankcase.

Water in the bottom of the crankcase can lead to engine damage and must be drained.

Change the oil immediately if the oil level rises.

CAUTION

Mixing brands or using a non-recommended oil may cause serious engine damage. Always use the

recommended oil. Never mix oil brands.

109

Maintenance

Engine Oil Level

Check the oil level before each use of the vehicle.

If the engine is cold, the oil level should be visible

at the lower edge of the sight glass. If the engine is

warm, the oil level should be visible at the center

of the sight glass.

A high oil level can cause engine overheating,

which could result in engine damage. Always

maintain the oil level as recommended.

1. Position the vehicle on a level surface.

2. View the oil level through the sight glass on

the right side of the vehicle.

3. Remove the fill plug and add the recom-

mended oil as needed.

4. Reinstall the fill plug.

Sight Glass

Fill Plug

Warm Level

Cold Level

110

Maintenance

Engine Oil Change

Always change the oil at the intervals outlined in the Periodic Maintenance Chart beginning

on page 97. Perform the initial break-in oil change after the first three hours of operation.

Always change both oil filters and clean the oil screens whenever changing oil.

NOTE: Change the oil more frequently on vehicles subjected to severe use.

CAUTION

If the ATV is left without oil in the system for extended periods, the oil pump may lose its prime,

which could result in engine damage. Do not allow the vehicle to be without oil and filter overnight.

Always replace the oil and filters within a few hours of draining the oil.

111

Maintenance

Engine Oil Change

1. Position the vehicle on a level surface.

NOTE: Remove the skid plate for better access to the

oil drain plug and short screen.

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

minutes. Stop the engine.

3. Place a drain pan beneath the crankcase.

Remove the drain plug. Allow the oil to drain

completely.

4. Clean the crankcase sealing surface and the drain plug (with magnet) thoroughly.

5. Replace the sealing ring. Reinstall the drain plug. Torque to 15 ft. lbs. (20 Nm).

CAUTION

Hot oil can cause serious burns to skin. Do not

allow hot oil to contact skin. Drain Plug

112

Maintenance

Engine Oil Change

Cleaning the Short Oil Screen

NOTE: Remove the skid plate for better access to the oil drain plug and short screen.

Hex Plug

View from bottom of vehicle

Front

113

Maintenance

Engine Oil Change

Cleaning the Short Oil Screen

1. Remove the plug at the bottom of the engine. See illustration on preceding page.

2. Remove the short oil screen from the plug. Clean the screen components thoroughly and

blow well with compressed air.

3. Check the O-rings. If damaged, install new O-rings.

4. Reinstall the screen to the plug.

5. Lubricate the threads and reinstall the plug. Torque to 7.5 ft. lbs. (10 Nm).

114

Maintenance

Engine Oil Change

Cleaning the Long Oil Screen

1. Remove the long screen plug, located

on the side of the engine near the engine

number.

2. Remove the oil screen. Clean the screen

thoroughly and blow with compressed

air.

3. Check the O-rings. If damaged, install

new O-rings.

4. Place the long oil screen on a pin-type

key or similar tool of about 12 inches

(300 mm) in length.

Plug

115

Maintenance

Engine Oil Change

Cleaning the Long Oil Screen

5. Insert the tool through the opening and into the bore of the opposite engine casing wall.

Push the oil screen into the casing as far as possible. Remove the tool.

6. Reinstall the plug. Torque to 11 ft. lbs. (15 Nm).

CAUTION

An improperly installed oil screen will

function poorly and result in increased

engine wear. Install the screen securely at

the angle shown in the illustration.

116

Maintenance

Engine Oil Change

Changing Oil Filters

1. Place a drain pan under the engine.

2. Remove the four oil filter cover screws (1).

Remove the covers.

3. Using circle clip (snap ring) pliers, pull the

oil filter inserts (2) out of the housing.

4. Thoroughly clean the engine casing, filter

covers and sealing surfaces of the O-rings.

Check the O-rings. If damaged, install new

O-rings.

5. Fill each oil filter with oil. Install the long

filter at the front of the filter box. Install the

short filter at the rear of the box.

117

Maintenance

Engine Oil Change

Changing Oil Filters

6. Grease the filter cover O-rings (3).

7. Reinstall the covers and the screws. Tighten

screws to 4.5 ft. lbs. (6 Nm).

8. Remove the oil fill plug (4). Add 1.7 qts. (1.6 l)

of the recommended engine oil (see page 108).

Reinstall the fill plug.

9. Start the engine. Allow it to idle for at least one

minute to fully distribute the new oil. Stop the

engine.

10. Check for leaks at all threaded connections and

at the oil filter covers.

11. View the oil level in the sight glass. Add oil as

needed to maintain the level as recommended

(see page 109).

118

Maintenance

Engine Cooling System

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.

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

completely drain the cooling system 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. See page 188

for the part numbers of Polaris products.

NOTE: Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water.

NOTE: Always follow the manufacturer's mixing recommendations for the freeze protection required

in your area.

119

Maintenance

Engine Cooling System

Coolant Level

The recovery bottle is located on the right side of

the vehicle under the front fender. The fluid level

must be maintained between the FULL and ADD

marks on the side panel (when the fluid is cool).

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: 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.

ADD

FULL

120

Maintenance

Engine Cooling System

Radiator Coolant Level

If the recovery bottle has run dry, inspect the level in the

radiator and add coolant if necessary. The radiator pressure

cap is located on the left side of the vehicle.

1. Remove the pressure cap.

2. Using a funnel, slowly add coolant as necessary

through the radiator filler neck.

3. Reinstall the pressure cap.

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.

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 cap.

Pressure

Cap

121

Maintenance

Engine Cooling System

Cooling System Bleeding

Bleeding the cooling system is required only if the system has been drained for maintenance

and/or repair. Always allow the engine to cool sufficiently before removing the radiator pres-

sure cap.

1. Remove the pressure cap.

2. Using a funnel, slowly add the recommended coolant. Fill the radiator to the bottom of

the filler neck.

3. Reinstall the pressure cap.

4. Start the engine and allow it to idle for five minutes, or until operating temperature is

reached.

5. Stop the engine.

6. After the engine has cooled, add additional coolant to refill the radiator to the bottom of

the filler neck.

7. Operate the vehicle for 20 minutes, allow the engine to cool, then recheck the coolant

level in the radiator. Add coolant as needed.

122

Maintenance

Air Filter Systems

NOTE: Refer to the illustrations on page 123.

1. Remove the seat.

2. Release the airbox cover clips and remove the cover.

3. Loosen the filter clamp. Remove the air filter from the box.

4. Locate the retaining spring.

5. Carefully remove the retaining spring from the filter.

6. Remove the inner and outer foam filter elements from the internal cage.

7. Separate the two filters. Wash the filters in soapy water, then rinse and let dry.

8. Apply a commercially available foam filter lubricant to the foam filters.

9. Reinstall all components.

10. Check the hoses for cracks, deterioration, abrasion, or leaks. Replace as needed.

123

Maintenance

Air Filter Systems

Step 3 Step 5Step 4

Step 7Step 6

124

Maintenance

Carburetor

Normal wear from engine vibrations may cause the carburetor to supply an overly rich fuel

mixture. Replace the jet needle and the needle jet after every 180 hours of operation.

Idle Speed

Carburetor idle adjustments affect engine starting

behavior. A proper idle speed of 1500-1600 RPM will

result in easier starting. If idle speed is unsatisfactory,

use the following procedure to make adjustments.

1. Position the vehicle on a level surface.

2. Lock the parking brake. Place the transmission in

neutral.

3. Start the engine and allow it to idle for five min-

utes, or until operating temperature is reached.

4. Turn the idle adjusting wheel (1) until idle speed reaches 1500-1600 RPM.

NOTE: If idle speed is unsatisfactory after performing this procedure, see your Polaris dealer for

information about jetting changes.

125

Maintenance

Carburetor

Carburetor Draining

Drain the carburetor float bowl at the intervals outlined in the

Periodic Maintenance Chart beginning on page 97. Always

drain the bowl after exposure to wet conditions. Perform this

procedure when the engine is cool.

1. Turn the fuel valve off.

2. Place a suitable container under the carburetor to collect

drained fluid.

3. Remove the hex plug (1). Allow fluids to drain.

4. Reinstall the hex plug securely.

126

Maintenance

Carburetor Jetting

Carburetor re-jetting can be performed to compensate for altitude and/or temperature

changes. If the vehicle is to be operated at various altitudes and temperatures, certain adjust-

ments can be made to improve its operation and driveability. Above 6000 feet (1800 m) the

engine air/fuel mixture becomes overly rich. An engine loses approximately 3% of its power

for each 1000-foot (305 m) increase in elevation. Although this power cannot be regained,

changes to the carburetor and drive system can be made to allow more efficient operation.

NOTE: Contact your dealer for altitude adjustments. Your dealer has the training and special tools

required to perform these modifications.

127

Maintenance

Lights

When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin

leaves a residue, causing a hot spot that will shorten the life of the lamp.

WARNING

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

dirty during normal operation. Wash the headlights frequently to maintain lighting quality.

Hot components can cause serious burns to skin. Do not service the headlamps until they've cooled

sufficiently.

128

Maintenance

Lights

Headlight Adjustment

1. Position the vehicle on a level surface with the head-

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

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

the headlight and make a mark on the wall at the

same height.

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

beam.

4. Observe the headlight aim on the wall. The most

intense part of the headlight beam should be aimed 2"

(5 cm) below the mark placed on the wall.

NOTE: Include rider weight on the seat when measuring.

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

6. Tighten the screw and torque to 27 in. lbs. (3 Nm).

Pivot

Screw

129

Maintenance

Lights

Headlight Lamp Replacement

1. Remove the wire harness connector from

the back of the headlight.

2. On the left headlamp, grasp the bulb

housing and turn it counterclockwise to

remove the bulb. On the right headlamp,

turn the bulb housing clockwise to

remove the bulb.

3. Apply dielectric grease to the socket and

install the new bulb. Rotate firmly.

NOTE: The bulb must be positioned so the

harness installs into the lamp at outer

side.

4. Reinstall the connector to the back of the

headlight.

Left Lamp

Counterclockwise

Right Lamp

Clockwise

130

Maintenance

Lights

Headlight Assembly Replacement

1. Remove the wire harness connector from the

headlights.

2. Remove the front cab (see page 133).

3. Remove the small adjuster bracket. Install it on

the new lamp.

4. Remove the large pivot bracket and remove the

headlamp.

5. Install the new headlamp by inserting the outboard

pivot pin in the hole of the mounting tab on the

cab.

Small Adjuster

Bracket

Large Pivot

Bracket

131

Maintenance

Lights

Headlight Assembly Replacement

6. Install the adjuster bracket onto the inboard pivot pin of the headlamp. Adjust for

approximately 1/16" clearance between the bracket and the edge of the headlight.

Tighten the mounting screws. IMPORTANT: Be sure the bracket is 90 degrees to the

pivot pin so the lamp can move freely.

7. Install the adjusting screw, leaving it loose so the headlight can be adjusted.

8. Reinstall the front cab. Connect the wire harness to the headlamp.

9. Adjust the lamps as needed (see page 128), then tighten the adjuster screw.

132

Maintenance

Lights

Brake Light Adjustment

Check the rear brake light for proper operation before

each use of the vehicle.

1. Turn the ignition key on.

2. Lightly apply and release the foot brake several times.

A properly operating rear brake light will immedi-

ately flash on and off with each movement of the

brake pedal.

3. If the light does not operate properly, grasp the switch

body with a pliers or similar tool and hold it lightly,

but securely. Using a wrench, rotate the adjustment

nut clockwise to increase tension on the spring.

NOTE: Rotate the adjusting nut counter-clockwise to decrease tension on the spring if the brake light

comes on when there is no pressure on the brake pedal.

4. Recheck and readjust as needed until the brake light operates properly.

Switch

Body

Adjustment

Nut

Spring

133

Maintenance

Front Cab Removal

1. Remove the left and right cab mount screws (1).

2. Remove the wire harness connector from the cab.

The connector is located under the left fender.

3. Remove the fuel tank cover screws (2).

4. Remove the four side panel screws (3).

5. Gently pull the cab upward to disengage it from

the stand-off. Place the cab upside down on a soft

protective surface to prevent scratching. 1

134

Maintenance

Side Panel Removal

1. Unlatch and remove the seat.

2. Remove the front cab.

3. Remove the screw securing the side panel.

4. Remove the side panel.

Side

Panel

Screw

135

Maintenance

Rear Cab Removal

1. Unlatch and remove the seat.

2. Remove the two lower bolts (1) on the

rear fenders of the cab.

3. Remove the two bolts (2), washers and

grommets (3) on the top of the cab.

4. Remove the cab.

136

Maintenance

Spark Plugs

Refer to the specifications section beginning on page 186 for recommended spark plug type

and gap.

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.

CAUTION

Using non-recommended spark plugs may result in serious engine damage and may void your

emission-related warranty. Always use Polaris-recommended spark plugs.

WARNING

A hot exhaust system and engine can cause serious burns. Wear protective gloves when removing

a spark plug for inspection. Allow components to cool before continuing.

137

Maintenance

Spark Plugs

Normal Plug

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

The electrodes are not burned or eroded. This indicates the proper type and heat range for the

engine and the service.

NOTE: The tip should not be white. A white insulator tip indicates overheating, caused by use of an

improper spark plug or incorrect carburetor/throttle body adjustments.

Wet Fouled Plug

The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a

carbon layer over the entire nose. Generally, the electrodes are not worn. General causes of

fouling are excessive oil, use of non-recommended oil, improper use of the choke, or incor-

rect carburetion adjustments.

138

Maintenance

Spark Plugs

Spark Plug Removal

1. Access the spark plug at the right side of the

engine.

2. Using the spark plug socket and a wrench,

rotate counterclockwise to remove the spark

plug.

3. After reinstalling the spark plug, torque to

14 ft. lbs. (19 Nm).

Spark

Plug

139

Maintenance

Spark Arrestor Clean-Out

To remove accumulated carbon, clean the spark arrestor at the intervals recommended in the

Periodic Maintenance Chart beginning on page 97.

WARNING

Failure to heed the following warnings while servicing the spark arrestor could result in serious injury

or death.

Do not perform clean-out immediately after the engine has been run, as the exhaust system

becomes very hot. Serious burns could result from contact with the exhaust components. Allow

components to cool sufficiently before proceeding.

Wear eye protection and gloves.

Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas that

can cause loss of consciousness or death in a very short time.

140

Maintenance

Spark Arrestor Clean-Out

NOTE: Refer to the illustration on page 141.

1. Remove the retaining screw and remove the arrestor from the end of the muffler.

2. Use a non-synthetic brush to clean the arrestor screen. A synthetic brush may melt if

components are warm.

NOTE: If necessary, blow debris from the screen with compressed air.

3. Inspect the screen for wear and damage. Replace a worn or damaged screen.

4. Reinstall the arrestor. Torque the screw to 5-7 ft. lbs. (7-9 Nm).

141

Maintenance

Spark Arrestor Clean-Out

Arrestor

Retaining

Screw

Screen

Muffler

142

Maintenance

Vehicle Immersion

If your ATV has been submerged or overturned in water deeper than the footpeg level, it's

critical to dry it promptly and properly before starting the engine.

Do not perform the following procedures if you don't feel completely capable, or if you sus-

pect that water has entered the fuel tank (likely if the water was deep or if the ATV over-

turned). Tow or trailer the ATV to your dealer for immediate service.

CAUTION

Do not start the engine after an ATV has been in water that exceeds the recommended depth.

Serious engine damage WILL occur. Tow or trailer the ATV to your dealer for service. In an

emergency, perform the temporary drying out procedure outlined below, which will allow short-term

operation only, to drive the ATV to a trailer or towing vehicle.

143

Maintenance

Vehicle Immersion

1. Turn the fuel valve off.

2. Drain water from the air box and clean the air filter. See page 122.

3. Drain the carburetor bowl. See page 125.

4. Remove the spark plug. See page 138.

5. Intermittently and briefly touch the starter button in half-second intervals to SLOWLY

rotate the engine three or four times. Water will eject from the spark plug hole.

(continued on following page)

WARNING

Fluids will be ejected through the spark plug hole and may cause serious injury to face or other body

parts. Stand clear of the spark plug while performing the following steps.

144

Maintenance

Vehicle Immersion

6. Press and hold the starter button for 10 second intervals for about one minute or until

water vapor is no longer ejecting from the spark plug hole.

7. Check the oil level. If the level is higher than the pre-ride inspection level, water has

entered the crankcase. Do not start the engine. Transport the vehicle to your dealer for

inspection and service. If the oil level is unchanged from the pre-ride inspection level,

replace the spark plug, start the engine and move the ATV promptly to a trailer or towing

vehicle.

CAUTION

If water isn't removed promptly from a submerged ATV, rust will form in precision components,

gears, bearings, the cylinder and other areas and result in serious engine damage. Always see your

dealer promptly after an ATV has been submerged.

145

Maintenance

Battery

The sealed battery is already filled with electrolyte and has been sealed and fully charged at

the factory. Never pry the sealing strip off or add any other fluid to this battery.

Keep the battery terminals and connections free of corrosion. If cleaning is necessary,

remove the 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.

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.

146

Maintenance

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.

Battery Removal

1. Remove the front cab (see page 133).

2. Disconnect the hold-down strap securing the battery in position.

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

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

5. Lift the battery out of the ATV.

147

Maintenance

Battery Installation

NOTE: Always install a fully charged battery. Using a new battery that has not been fully charged can

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

recharging is necessary, use a .5 amp battery charger.

1. Place the battery in the battery holder.

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

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

4. Attach the hold-down strap.

5. Reinstall the front cab.

6. Verify that cables are properly routed.

148

Maintenance

Battery Charging (Sealed Battery)

On a sealed battery, the sealing strip cannot be removed. Use a voltmeter or multimeter to

measure DC voltage. A fully charged battery will register 12.8 V or higher. If the voltage is

less than 12.8 volts, recharge the battery.

The battery may be recharged without removing

it from the vehicle. Use the remote charging ter-

minals under the right front cab.

NOTE: The Polaris Battery Tender battery charger

can be left connected during the storage

period and will automatically charge the

battery if the voltage drops below a pre-

determined point.

NOTE: If the battery fails to recharge during vehicle

operation, check voltage regulator connec-

tions. See your Polaris dealer for inspection

of the voltage regulator and generator.

Charging

Te r m i n a l

149

Maintenance

Battery Charging (Sealed Battery)

When using an automatic charger such as the Polaris Battery Tender, refer to the manufac-

turer's instructions for recharging. When using a constant current charger, use the guidelines

on the following page for recharging.

WARNING

An overheated battery could explode, causing severe injury or death. Always watch charging times

carefully. Stop charging if the battery becomes very warm to the touch. Allow it to cool before

resuming charging.

150

Maintenance

Battery Charging (Sealed Battery)

NOTE: Always verify battery condition before and 1-2 hours after the end of charging.

State of

Charge Voltage Action

Charge Time

(Using constant current

charger @ standard amps

specified on top of battery)

100% 12.8-13.0 volts None, check at 3 months from

date of manufacture

None required

75%-100% 12.5-12.8 volts May need slight charge, if no

charge given, check in 3

months

3-6 hours

50%-75% 12.0-12.5 volts Needs charge 5-11 hours

25%-50% 11.5-12.0 volts Needs charge At least 13 hours, verify

state of charge

0%-25% 11.5 volts or less Needs charge with desulfating

charger

At least 20 hours

151

Maintenance

Tires

Tire Tread Depth

Always replace tires when tread depth is

worn to 1/8" (3 mm) or less.

WARNING

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

installed tires will affect vehicle handling and could cause an accident resulting in serious injury or

death.

Maintain proper tire pressure as described on the decal on your ATV and in the owner's manual.

Always use original equipment size and type when replacing tires.

Make sure the wheels are installed properly.

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

1/8" (3 mm)

152

Maintenance

Wheel Nut Torque Specifications

Check the wheel nut torques occasionally and when they've been loosened for maintenance.

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. Stop the engine. Place the transmission in gear. Lock the parking brake.

2. Loosen the wheel bolts slightly.

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

4. Remove the wheel nuts and remove the wheel.

Bolt Location & Size Torque Specification

Front 3/8" 30-35 ft. lbs. (40-47 Nm)

Rear 3/8" 30-35 ft. lbs. (40-47 Nm)

153

Maintenance

Wheel Installation

1. Place the transmission in gear. Lock the parking

brake.

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

stem toward the outside and rotation arrow on the

tire pointing toward forward rotation.

3. Install the wheel bolts and finger tighten them.

4. Lower the vehicle to the ground.

5. Securely tighten the bolts to specification. See

page 152.

WARNING

Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in

serious injury or death. Never install the rim with the valve stem to the inside of the vehicle. Always

ensure that all nuts are torqued to specification.

Valve

Stem

154

Maintenance

Boot Inspection

Before Operating

Inspect the boots before operating the vehicle. If a boot is

torn, punctured or leaking fluid, see your Polaris dealer for

service or replacement.

After Operating

Inspect the boots after operating the vehicle. If a boot is

bulging or ballooned, perform the boot burping procedure

on page 155. Good Boot

Bulging Boot

155

Maintenance

Boot Burping

1. Using a needle nose pliers or boot clamp removal

tool, remove the small boot clamp (1) from the

inboard boot.

NOTE: Do not use any tools that may damage the boot.

2. Slide the free end of the boot two inches toward the

center of the vehicle and lift the boot away from the

shaft to allow excess air to escape (2).

3. Wipe excess grease from the shaft before returning

the boot to the boot groove. Use caution not to allow

excess air back into the system when reinstalling the

boot.

4. Reinstall the boot clamp.

156

Maintenance

Clutch System Bleeding

Always bleed the clutch system at the intervals out-

lined in the Periodic Maintenance Chart beginning on

page 97. Always bleed the clutch system any time the

clutch lever feels unresponsive.

Always use the recommended fluid when bleeding

the clutch system. See page 55.

1. Position the vehicle on a level surface. Turn the

handlebar until the master cylinder is in a hori-

zontal position.

2. Remove the two cover screws, the cover and the

rubber boot.

3. Fill a bleeder syringe (1) with the recommended

hydraulic clutch oil.

157

Maintenance

Clutch System Bleeding

4. Remove the bleeder screw (2) from the slave cylinder.

5. Press fluid into the system until the fluid runs out of the hole (3) in the master cylinder

without producing bubbles.

NOTE: Extract fluid from the master cylinder during the process to prevent overflowing.

6. When finished, remove the bleeder syringe.

7. Reinstall the bleeder screw.

8. Add or remove fluid as needed to maintain the level 4mm below the top edge of the mas-

ter cylinder reservoir.

9. Reinstall the cover, boot and screws securely.

158

Maintenance

Throttle Lever Freeplay

Periodically check throttle lever freeplay.

Maintain freeplay between 1/16" and 1/8"

(1.5 - 3 mm).

If adjustments are needed, use the procedure

on page 159.

1/16" - 1/8"

(1.5 - 3 mm)

159

Maintenance

Throttle Cable Freeplay Adjustment

1. Locate the throttle cable at the handlebar.

2. Slide the boots off the inline cable adjuster

sleeve and loosen the locking nut.

3. Turn the adjuster until 1/16" to 1/8" (1.5-3 mm)

freeplay is achieved at the thumb lever.

NOTE: While adjusting freeplay, be sure to flip the

throttle lever back and forth.

4. Tighten the locknut and slide the boots over the cable adjuster until they touch at the

midpoint of the adjuster.

WARNING

Improper adjustment of throttle cable freeplay can result in loss of control, which could result in

serious injury or death. Polaris recommends that this procedure be performed by a Polaris dealer to

ensure that it's done correctly. Mechanically knowledgeable persons who perform this procedure

must follow the adjustment procedures exactly.

Boot Boot

Sleeve Locking Nut

160

Maintenance

Brakes

Both brakes are self-adjusting, but the following checks are recommended to keep the brake

systems in good operating condition. Check more often if brakes are used heavily under nor-

mal operation.

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.

161

Maintenance

Brakes

1. Always maintain brake fluid at the recommended level. See

pages 60-61.

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.

6. Inspect the rear brake disc spline and pad wear surface for

excessive wear.

NOTE: Pads should be changed when worn to 3/64" (1 mm). 3/64" (1 mm)

162

Maintenance

Toe Alignment

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

designed for a neutral toe setting.

1. Position the vehicle on a level surface.

2. Place the handlebars in a straight-ahead position. Use tie straps to secure the handlebars

to the rear grab bar so they can't move.

3. Place stands in front of the vehicle, perpendicular to the rear tires. See illustration.

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.

163

Maintenance

Toe Alignment

4. 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.

5. Measure the distance between the string in

front of the rear tires (1) and in front of the

front tires (2). If the two measurements are not

equal, adjust the string position until the mea-

surements are equal.

6. Measure the distance from the string to the rim

at the front (3) and rear (4) of the front rim.

The difference between these two measure-

ments should be between 0" and 1/16" (0-1.5

mm) toe out.

NOTE: If you discover improper alignment, see your

Polaris dealer for service.

Stands

String

164

Maintenance

Chain Tension

Check the amount of chain slack by moving

the vehicle slightly forward to remove slack

at the top side of the chain. At the center

point of the top side of the chain there should

be 1/4"-3/8" (6-9 mm) deflection.

Use the procedure on the following page if

the chain needs adjustment.

NOTE: The chain has a press-on master link. A

chain tool must be used if it's necessary

to remove the chain for service.

CAUTION

Never adjust or operate the vehicle with the rear drive chain too loose or too tight. Severe damage

to the transmission and drive components can result.

165

Maintenance

Chain Tension

1. Loosen the upper and lower pivot mounting bolts (1).

2. Thread the chain adjusting bolt (2) inward or outward to adjust chain slack to the proper

dimension.

3. Tighten the pivot mounting bolts to 30 ft. lbs. (40 Nm).

4. Torque the chain adjusting bolt to 17 ft. lbs. (23 Nm).

Proper splicelink clip

opening position

166

Maintenance

Handlebar Adjustment

The handlebars can be adjusted for rider preference.

1. Loosen the four handlebar bolts.

2. 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.

3. Torque the two front bolts to 10-12 ft. lbs. (14-16 Nm),

then torque the two rear bolts.

NOTE: A gap of up to 1/8" (3 mm) will remain at the rear bolts.

4. Check sprocket bolt torque. Torque to 30 ft. lbs. (40

Nm).

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.

Loosen

bolts

167

Maintenance

Steering Inspection

Check the steering assembly periodically for loose nuts and bolts. If loose nuts and bolts are

found, or if you notice any freeplay in the steering post, see your Polaris dealer for service

before operating the vehicle.

Camber and Caster

The camber and caster are non-adjustable.

168

Maintenance

Front Suspension

Suspension Set-Up

1. Position the vehicle on a level surface.

2. Stop the engine.

3. Elevate the front of the vehicle by placing

a suitable stand under the frame.

NOTE: The tires should be barely touching the

ground and the suspension should be at

full rebound.

4. Measure the distance from the ground to

the bottom of the lower front bumper bolt.

Note this measurement for later use.

5. Remove the stand and have a rider sit

comfortably on the seat with hands on the

handlebars.

169

Maintenance

Front Suspension

Suspension Set-Up

6. Place the transmission in neutral and slowly roll the machine forward and rearward at

least ten feet (3 m) without lifting or pushing down on the suspension.

7. Turn the handlebars fully to the left and right.

8. With the rider still on the vehicle, repeat the measurement performed in step 4. Subtract

the step 8 measurement from the step 4 measurement. The difference should be between

3.75 and 4 inches (9.5-10.2 cm).

9. If the number is less than 3.75 inches (9.5 cm), decrease the front spring preload (see

page 170) and repeat all steps. If the number is higher than 4 inches (10.2 cm), increase

spring preload and repeat all steps.

170

Maintenance

Front Suspension

Spring Preload

The front suspension preload may be adjusted to suit different riding conditions and operator

weight.

WARNING

Uneven adjustment may cause poor handling of the ATV, which could result in an accident and

serious injury or death. Always adjust both the left and right spring preloads equally or have your

Polaris dealer perform the adjustments.

171

Maintenance

Front Suspension

Spring Preload

1. Raise and safely support the front of the vehicle

off the ground to allow the suspension to fully

extend.

2. Loosen the jam nut.

3. Turn the adjusting ring clockwise to increase

preload (1). Turn the ring counter-clockwise to

decrease preload (2).

4. Tighten the jam nut against the adjusting ring.

Adjusting

Ring

Jam Nut

172

Maintenance

Rear Suspension

Suspension Set-Up

1. Position the vehicle on a level surface.

2. Stop the engine.

3. Elevate the rear of the vehicle by plac-

ing a suitable stand under the frame.

NOTE: The tires should be barely touching the

ground and the suspension should be

at full rebound.

4. Measure the distance from the ground

to the bottom of the rear lower control

arm pivot bolt. Note this measurement

for later use.

173

Maintenance

Rear Suspension

Suspension Set-Up

5. Remove the stand and have a rider sit comfortably on the seat with hands on the handle-

bars.

6. Place the transmission in neutral and slowly roll the machine forward and rearward at

least ten feet (3 m) without lifting or pushing down on the suspension.

7. Turn the handlebars fully to the left and right.

8. With the rider still on the vehicle, repeat the measurement performed in step 4.

9. Subtract the step 8 measurement from the step 4 measurement. The difference should be

between 4 and 4.25 inches (10.2-10.8 cm).

10. If the number is less than 4 inches (10.2 cm), decrease the rear spring preload on both

shocks (see page 175) and repeat all steps. If the number is higher than 4.25 inches (10.8

cm), increase spring preload and repeat all steps.

174

Maintenance

Rear Suspension

When the adjuster screw is turned counter-clockwise until it stops, the damping is in the soft-

est position (position #1). Turn the screw clockwise to increase damping.

NOTE: Use a flat blade screwdriver to make damping adjustments.

Rear Shock

Setting Compression Damping

Softest Position #1

Factory Position #4

Firmest Position #7

175

Maintenance

Rear Suspension

The rear suspension spring preload, shock rebound

damping and shock compression damping may be

adjusted to suit different riding conditions and operator

weight.

Spring Preload

1. Raise and safely support the rear of the vehicle off

the ground to allow the suspension to fully extend.

2. Turn the adjusting ring clockwise (1) to increase

preload. Turn the ring counter-clockwise (2) to

decrease preload.

Adjusting

Ring

176

Maintenance

Rear Suspension

Compression Damping

The compression damping clickers are located on the

bottom of the shocks (on the lower clevis). Use a

screwdriver to make adjustments.

To set the shock at the softest setting (position #1) turn

the screw counter-clockwise until it stops. From this

position, turn the screw clockwise to increase com-

pression damping.

Setting Compression Damping

Softest Position #1

Factory Position #4

Firmest Position #7 Clicker

177

Maintenance

Cleaning

Keeping your vehicle clean will not only improve its appearance but it can also extend the

life of various components.

CAUTION

High water pressure may damage components. Polaris recommends washing the vehicle by hand

or with a garden hose, using mild soap.

Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not

allow these types of products to contact the vehicle.

178

Maintenance

Cleaning

Washing the Vehicle

The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild

soap and water.

1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts

last.

2. Rinse with clean water frequently.

3. Dry surfaces with a chamois to prevent water spots.

Washing Tips

• Avoid the use of harsh cleaners, which can scratch the finish.

• Do not use a power washer to clean the vehicle.

• Do not use medium to heavy duty compounds on the finish.

• Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and

pads may contain dirt particles that will scratch the finish.

179

Maintenance

Cleaning

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:

• Wheel bearings

• Electrical components and wiring

• Transmission seals

•Brakes

• Cab and body panels

• 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.

180

Maintenance

Polishing

Polaris recommends the use of common household aerosol furniture polish for polishing the

finish on your Polaris vehicle. Follow the instructions on the container.

Polishing Tips

• Avoid the use of automotive products, some of which can scratch the finish of your vehi-

cle.

• Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and

pads may contain dirt particles that will scratch the finish.

181

Maintenance

Storage

Exterior

Make necessary repairs and clean the vehicle as recommended. See page 177.

Battery Storage

Refer to pages 145-150 for battery storage and battery charging procedures.

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.

182

Maintenance

Storage

Engine Oil

Change the oil and both filters. Clean the oil screens. See page 110.

Air Filter / Air Box

Inspect and clean (or replace) the air filter. Clean the air box. Drain the sediment tube.

Fluid Levels

Inspect fluid levels. Change fluids as recommended in the Periodic Maintenance Chart

beginning on page 97.

• Transmission Oil

•Engine Oil

• Coolant (test strength/fill)

•Brake Fluid

• Clutch Fluid

183

Maintenance

Storage

Stabilize the Fuel

1. Fill the fuel tank with fuel.

2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instruc-

tions on the container for the recommended amount.

NOTE: Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits

from pistons, rings, valves and exhaust systems. It also prevents bacterial growth and pro-

motes better starting after the storage period.

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

through the fuel in the tank and carburetor.

4. Stop the engine. Turn the fuel valve off.

5. Start the engine. Allow the engine to operate until it stops.

6. Drain the carburetor bowl. See page 125.

7. Remove the spark plug. Pour approximately 5 cc of engine oil into the cylinder through

the opening. Using the start button, rotate the engine several times to distribute the oil

onto the cylinder walls. Reinstall the spark plug. Torque to specification.

184

Maintenance

Storage

Lubricate

Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Main-

tenance Chart beginning on page 97.

Storage Area/Covers

1. Make sure tire pressure is at specification.

2. Be sure the storage area is well ventilated.

3. Using suitable supports under the frame, raise the vehicle slightly so that the tires are not

touching the ground.

4. Cover the vehicle with an appropriate cover.

NOTE: Do not use plastic or coated materials. They do not allow enough ventilation to prevent con-

densation, and may promote corrosion and oxidation.

185

Maintenance

Transporting the ATV

Follow these procedures when transporting the vehicle.

1. Stop the engine.

2. Place the transmission in first gear.

3. Lock the parking brake.

4. Remove the key to prevent loss during transporting.

5. Secure the fuel cap, oil cap and seat.

6. Turn the fuel valve off.

7. Always tie the frame of the ATV to the transporting unit

securely with suitable straps or rope.

186

Specifications

Outlaw 525 IRS

Max. Weight Capacity 215 lbs./97.5 kg Pilot Jet 45

Dry Weight 395 lbs./179 kg Main Jet 148

Fuel Capacity 3.9 gal./14.8 l Needle Jet OBDVS

Overall Length 71.5 in./182 cm Needle Clip #4

Overall Width 47.5 in./121 cm Slow Air Jet 100

Overall Height 45 in./114 cm Alternator Output 200 w @ 3000 RPM

Wheelbase 51 in./130 cm Compression Ratio 11:1

Ground Clearance 11.5 in./29 cm Starting System Electric

Min. Turning Radius 67 in./170 cm Carburetor Keihin FCR-MX 39mm

Engine Oil Capacity 1.7 qts./1.6 l Ignition System CDI

Coolant Capacity 2.25 qts./2.1 l Ignition Timing 25° +/- 3° @ 3500 RPM in

neutral

Engine ES51KLE Spark Plug Type NGK DCPR8E

Displacement 510 cc Spark Plug Gap 0.6 mm / .024 in.

Bore x Stroke 95 x 72 mm Lubrication System Dry Sump/Internal Reservoir

187

Specifications

Jetting Chart

Outlaw 525 IRS

Driving System Type Rear Two-Wheel Drive Tire Size - Front 21 x 7R10

Shift Type 5-Speed Manual Shift Tire Size - Rear 20 x 10R9

Primary Ratio 2.516 Tire Pressure - All 4 psi/27.6 KPa

Gear Ratio - 1st 2.500 Front Brake Hydraulic Disc, Dual Bore

Gear Ratio - 2nd 1.941 Rear Brake Hydraulic Disc

Gear Ratio - 3rd 1.579 Parking Brake Hydraulic lock, front wheel

Gear Ratio - 4th 1.333 Headlights 2 Dual Beam (35w/35w)

Gear Ratio - 5th 1.130 Taillights LED

Gear Ratio - Reverse 2.429 Brakelight 26.9w

ALTITUDE

Meters (Feet)

AMBIENT TEMPERATURE

Below 40° F (Below 5° C) +40°F and above (+5°C and above)

0-1800 (0-6000) Main Jet: 158

Needle Clip Position: #4

Main Jet: 148

Needle Clip Position: #4

1800-3700

(6000-12000)

Main Jet: 148

Needle Clip Position: #3

Main Jet: 138

Needle Clip Position: #3

188

Polaris Products

Part Number Description

Engine Lubricant

2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt.)

2876245 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal.)

Grease / Specialized Lubricants

2871312 Grease Gun Kit, Premium All Season (3 oz.)

2871322 Premium All Season Grease (3 oz. cartridge)

2871423 Premium All Season Grease (14 oz. cartridge)

2871460 Starter Drive Grease (2 oz.)

2871329 Dielectric Grease (Nyogelt)

2872073 Chain Lube, Aerosol (6.25 oz.)

2872348 Chain Lube, Aerosol (16 oz.)

1350046 Rear Shaft Grease (30 g)

189

Polaris Products

Part Number Description

Coolant

2871323 60/40 Coolant (gal.)

2871534 60/40 Coolant (qt.)

Additives / Miscellaneous

2871326 Carbon Clean Plus (12 oz.)

2870652 Fuel Stabilizer (16 oz.)

2872189 DOT4 Brake Fluid (12 oz.)

2876335 Hydraulic Clutch Oil (qt.)

190

Troubleshooting

See your Polaris dealer if you're unable to identify solutions using the following charts.

Engine Turns Over, Fails to Start

Possible Cause Solution

Out of fuel Turn the fuel valve to reserve, refuel

Water is present in carburetor or fuel supply Clean carburetor and/or drain fuel system and refuel

Fuel valve is turned off Turn the fuel valve on

Engine is cold Use choke to start a cold engine

Interrupted fuel supply Turn the fuel valve off; remove the fuel hose at the

carburetor and place in a drain pan; turn the fuel valve

on.

• If fuel leaks out, clean the carburetor.

• If no fuel leaks out, clean the fuel valve.

Clogged fuel valve or filter Inspect and clean or replace

Old or non-recommended fuel Replace with new fuel

Fouled or defective spark plug(s) Inspect and clean or replace plug(s)

Incorrect spark plug gap Adjust gap to specification

191

Troubleshooting

Engine Turns Over, Fails to Start

Possible Cause Solution

No spark to spark plug Inspect, clean and/or replace spark plugs

See your Polaris dealer

Overuse of choke/flooded engine Engage starter 2 times for 5 seconds each, then restart.

If engine fails to start, inspect, clean and/or replace

spark plugs.

Low battery voltage Recharge battery to 12.8 VDC

Ignition system or other mechanical failure See your Polaris dealer

Throttle ETC switch not opening Adjust throttle freeplay

The plug connection of the CDI-unit, pulse generator

or ignition coil has oxidized Clean the plug connection and treat with contact spray

192

Troubleshooting

Engine Doesn’t Turn Over

Engine Pings or Knocks

Possible Cause Solution

Fuseable link See Polaris dealer for replacement

Low battery voltage Recharge battery to 12.8 VDC

Loose battery connections Check all connections and tighten

Loose solenoid connections Check all connections and tighten

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

193

Troubleshooting

Engine Backfires

Possible Cause Solution

Weak, fouled or defective spark plug 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

Exhaust leak Inspect system for leaks; see your Polaris dealer

Incorrectly installed spark plug wire See your Polaris dealer

Incorrect ignition timing See your Polaris dealer

Mechanical failure See your Polaris dealer

194

Troubleshooting

Engine Runs Irregularly, Stalls or Misfires

Possible Cause Solution

Fouled or defective spark plug Inspect, clean and/or replace spark plug

Worn or defective spark plug wire See your Polaris dealer

Incorrect spark plug gap or heat range Set gap to specs or replace plug

Loose ignition connections Check all connections and tighten

Defective ignition system See your Polaris dealer

Water present in fuel Replace with new fuel

Low battery voltage Recharge battery to 12.8 VDC or replace

Kinked or plugged fuel vent line Inspect and replace

Old or non-recommended fuel Replace with recommended fuel

195

Troubleshooting

Engine Runs Irregularly, Stalls or Misfires

Possible Cause Solution

Clogged air filter Inspect and clean or replace

Electronic throttle control malfunction See your Polaris dealer

Incorrect idle adjustment Adjust idle speed or see your Polaris dealer

Clogged idle jet Disassemble carburetor and clean the jets

Other mechanical failure See your Polaris dealer

196

Troubleshooting

Engine Runs Irregularly, Stalls or Misfires

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

Old or non-recommended fuel Replace with recommended fuel

Clogged fuel valve screen See your Polaris dealer

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 recommended octane fuel

Incorrect jetting See your Polaris dealer

Plugged, dirty or wet air filter Clean pre-filter, replace main filter as needed

197

Troubleshooting

Engine Fails to Reach High RPM

Engine Uses Excessive Oil

Possible Cause Solution

Worn or dirty needle valve Clean and/or replace needle valve

Loose carburetor jets Tighten jets

Faulty ignition timing See your Polaris dealer

Possible Cause Solution

Bent engine ventilation hose Install a new hose

Excessive oil in system Check oil level, maintain at recommended level

Use of non-recommended oil (too thin) Replace with a recommended oil

198

Troubleshooting

Engine Stops or Loses Power

Possible Cause Solution

Out of fuel Turn the fuel valve to reserve, refuel

Interrupted fuel supply Clean fuel system and carburetor

Clogged, dirty or wet air filter Inspect and clean or replace

Electronic throttle control malfunction See your Polaris dealer

Other mechanical failure See your Polaris dealer

Overheated engine Clean radiator screen and core if equipped

Clean engine exterior

See your Polaris dealer

199

Troubleshooting

Engine Stops or Loses Power

Possible Cause Solution

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 plug Inspect, clean and/or replace spark plugs

Worn or defective spark plug wire 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 12.8 VDC

Old or non-recommended fuel Replace with recommended fuel

200

Troubleshooting

Engine Overheats

Possible Cause Solution

Debris lodged in screen Remove and clean the screen

Plugged radiator Use a garden hose to flush any debris from the radia-

tor fins. NOTE: High pressure washers can deform the

radiator fins and reduce cooling efficiency.

Insufficient coolant Check levels and fill as needed; check for leaks

Insufficient air flow due to slow operation Operate at a faster speed to increase air flow

Cooling system has not been bled Bleed the cooling system

Foam has formed in cooling system Drain and replace coolant with recommended coolant

Bent cooling hose Shorten or replace hose

Defective thermostat or thermoswitch See your Polaris dealer

Blown fan fuse or defective fan Replace fuse and check fan for proper operation or see

your Polaris dealer

201

Troubleshooting

Engine Fails to Reach Full Power

Possible Cause Solution

Interrupted fuel supply Clean fuel system and carburetor

Float leaks Replace the float

Clogged, dirty or wet air filter Inspect and clean or replace

Faulty exhaust system Check system for damage; see your Polaris dealer

Valve gap is too small Adjust valve gap

Faulty ignition timing See your Polaris dealer

202

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 REGIS-

TERED 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.

203

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 war-

ranty 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 war-

ranty does not cover physical damage to paint or finish, stress cracks, tearing or puncturing of upholstery mate-

rial, 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 replace-

ment of any defective materials, or components or products. THE REMEDIES SET FORTH IN THIS WAR-

RANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS

WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSE-

QUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS

OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHER-

WISE. 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.

204

Warranty

WARRANTY COVERAGE AND EXCLUSIONS:

LIMITATIONS OF WARRANTIES AND REMEDIES

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF

MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO

THE ABOVE SIX MONTH 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.

205

Warranty

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 personnel at Polaris.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

If any of the above terms are void because of state or federal law, all other warranty terms will remain in effect.

Engine Oil

1. Mixing oil brands or using non-recommended oil may cause engine damage. We recommend the use of Polaris

engine oil.

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

Spark Arrestor

Polaris warrants that the spark arrestor in this vehicle will meet the efficiency requirements of 43 CFR 8343.1(c)

for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance

with Polaris recommendations.

206

Warranty

EXPORTED VEHICLES

EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BUL-

LETIN 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 war-

ranty 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 out-

side the country of the selling dealer's authorized location.

This policy does not apply to Safety Recalls.

207

Warranty

EXPORTED VEHICLES

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 sell-

ing 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.

208

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 proce-

dure 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: 1-888-704-5290

Canada: 1-204-925-7100

209

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 pur-

chaser and ends 30 months (2.5 years) after that date, after 5000 km (3100 miles), or after 500 hours of operation,

whichever comes first.

This emission-related warranty covers components whose failure would increase an engine's emissions, including

electronic controls, fuel injection, exhaust-gas 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.

210

Warranty

U.S.A. EPA Emissions Limited Warranty

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 LIM-

ITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS

WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSE-

QUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION,WHETHER ARISING OUT OF EXPRESS

OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR OTHER-

WISE.

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 com-

petition. This limited warranty also does not cover physical damage, corrosion or defects caused by fire, explo-

sions 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 War-

ranty Department at 1-888-704-5290.

211

Maintenance Log

Present this section of your manual to your dealer each time your vehicle is serviced. This will provide you and

future owners with an accurate log of maintenance and services performed.

DATE SERVICE

INTERVAL

(HOURS)

TECHNICIAN SERVICE PERFORMED / COMMENTS

3 Hours

(Break-in)

212

Maintenance Log

DATE SERVICE

INTERVAL

(HOURS)

TECHNICIAN SERVICE PERFORMED / COMMENTS

213

Maintenance Log

DATE SERVICE

INTERVAL

(HOURS)

TECHNICIAN SERVICE PERFORMED / COMMENTS

214

Maintenance Log

DATE SERVICE

INTERVAL

(HOURS)

TECHNICIAN SERVICE PERFORMED / COMMENTS

215

Index

Age Restrictions . . . . . . . . . . . . . . 14

Air Filter Systems . . . . . . . . . 122-123

Battery

Charging. . . . . . . . . . . . 148-150

Installation . . . . . . . . . . . . . 147

Maintenance. . . . . . . . . . . . 145

Removal . . . . . . . . . . . . . . . 146

Storage . . . . . . . . . . . . 146, 181

Bleeding the Cooling System . . . 121

Boots . . . . . . . . . . . . . . . . . . . . . . . 13

Brake Fluid . . . . . . . . . . . . . . . . 60-61

Brake Light Adjustment . . . . . . . 132

Brake Maintenance . . . . . . . . 160-161

Brakes

Foot Brake . . . . . . . . . . . . . . 58

Hand Brake . . . . . . . . . . . . . 59

Parking Brake . . . . . . . . . 62-63

Break-in Period . . . . . . . . . . . . . 70-71

Cab Removal, Front . . . . . . . . . . . 133

Cab Removal, Rear . . . . . . . . . . . 135

Camber and Caster . . . . . . . . . . . . 167

Carburetor . . . . . . . . . . . . . . 124-125

Carburetor Draining . . . . . . . . . . . 125

Carburetor Jetting. . . . . . . . . . . . . 126

Chain Tension . . . . . . . . . . . 164-165

Choke . . . . . . . . . . . . . . . . . . . . . . . 70

Cleaning . . . . . . . . . . . . . . . . 177-179

Clothing . . . . . . . . . . . . . . . . . . . . . 13

Clutch Fluid . . . . . . . . . . . . . . . . . . 55

Clutch Lever. . . . . . . . . . . . . . . . . . 54

Clutch System Bleeding. . . . 156-157

Compression Damping, Rear . . . . 176

Consumer Product Safety. . . . . . . . 22

Coolant Level, Radiator . . . . . . . . 120

Coolant Level, Recovery Bottle. . 119

Cooling System . . . . . . . . . . 118-121

Cooling System Bleeding. . . . . . . 121

Deceleration . . . . . . . . . . . . . . . . . 67

Driving Across Hillsides . . . . . . 84-85

Driving Downhill . . . . . . . . . . . . . 88

Driving in Reverse . . . . . . . . . . 92-93

Driving on Slippery Surfaces . . 80-81

Driving Over Obstacles. . . . . . . . . 94

Driving Procedure . . . . . . . . . . . . . 78

Driving Through Water. . . . . . . 90-91

Driving Uphill . . . . . . . . . . . . . . 82-83

Electronic Throttle Control . . . . . . 57

Emission Control Systems . . . . 95-96

Engine Idle Speed . . . . . . . . . . . . 124

Equipment Modifications . . . . . . . 23

Eye Protection . . . . . . . . . . . . . . . . 13

216

INDEX

Fluid

Brake . . . . . . . . . . . . . . . . 60-61

Clutch . . . . . . . . . . . . . . . . . . 55

Foot Brake . . . . . . . . . . . . . . . . . . . 58

Foot Brake Fluid Level . . . . . . . . . 61

Fuel Filter . . . . . . . . . . . . . . . . . . . . 68

Fuel Stabilizer . . . . . . . . . . . . . . . 183

Fuel System . . . . . . . . . . . . . . . . . . 74

Fuel Tank . . . . . . . . . . . . . . . . . . . . 68

Fuel Valve . . . . . . . . . . . . . . . . . . . 69

G-H

Gloves. . . . . . . . . . . . . . . . . . . . . . . 13

Hand Brake. . . . . . . . . . . . . . . . . . . 59

Hand Brake Fluid Level . . . . . . . . . 61

Handlebar Adjustment . . . . . . . . . 166

Headlight Adjustment . . . . . . . . . 128

Headlight Assembly . . . . . . . 130-131

Headlights. . . . . . . . . . . . . . . . . . . . 53

Helmet . . . . . . . . . . . . . . . . . . . . . . 12

I-J-K

Idle Speed . . . . . . . . . . . . . . . . . . 124

Indicator Lights . . . . . . . . . . . . . . . 52

Jetting . . . . . . . . . . . . . . . . . 126, 187

Key Switch . . . . . . . . . . . . . . . . . . 51

K-Turn . . . . . . . . . . . . . . . . . . . . . . 86

Lights . . . . . . . . . . . . 52-53, 127-132

Brake Light. . . . . . . . . . . . . 132

Headlight Adjustment. . . . . 128

Headlight Assembly . . 130-131

Headlights. . . . . . . . . . . . . . . 53

Indicator Lights . . . . . . . . . . 52

Maintenance Chart. . . . . . . . . 97-107

Making Turns . . . . . . . . . . . . . . . . 79

Manual Shift . . . . . . . . . . . . . . 64-67

Master Cylinder . . . . . . . . . . . . 60-61

Modifications. . . . . . . . . . . . . . . . . 23

Oil Change, Engine. . . . . . . . 110-117

Oil Level, Engine . . . . . . . . . . . . . 109

Oil Recommendations . . . . . . . . . 108

Operator Restrictions . . . . . . . . . . . 14

Operator Safety. . . . . . . . . . . . . 14-49

Parking Brake . . . . . . . . . . . . . . 62-63

Parking on a Hill or Incline . . . . . . 89

Passenger Warning . . . . . . . . . . . . . 11

Periodic Maintenance Chart . . 97-107

Polaris Products . . . . . . . . . . . . . . 188

Polishing . . . . . . . . . . . . . . . . . . . . 180

Pre-Ride Inspection . . . . . . . . . 72-73

Restrictions . . . . . . . . . . . . . . . . . . . 14

Reverse Lock-Out Switch. . . . . . . . 66

Riding Gear. . . . . . . . . . . . . . . . 12-13

217

INDEX

Safety Decals

Age 16 Warning. . . . . . . . . . 10

Discretionary Warning. . . . . 10

General Warning . . . . . . . . . . 9

No Passenger Warning. . . . . 11

Sport ATV Warning. . . . . . . 10

Tire Pressure/Load Warning 11

Safety Training . . . . . . . . . . . . . . . 15

Severe Use . . . . . . . . . . . . . . . . . . 97

Shift Pedal. . . . . . . . . . . . . . . . . . . 64

Shifting Gears . . . . . . . . . . . . . . . . 65

Side Panel Removal . . . . . . . . . . 134

Signal words . . . . . . . . . . . . . . . . . 16

Spark Arrestor Clean-Out . . . 139-141

Spark Plug Removal . . . . . . . . . . 138

Spark Plugs . . . . . . . . . . . . . . 136-138

Spring Preload. . . . . . . . . . . . . . . 170

Spring Preload, Front . . . . . . . . . 171

Spring Preload, Rear . . . . . . . . . . 175

Starting the Engine . . . . . . . . . . 75-77

Steering Inspection. . . . . . . . . . . . 167

Storage . . . . . . . . . . . . . . . . . 181-184

Suspension

Front . . . . . . . . . . . . . . 168-171

Rear . . . . . . . . . . . . . . . 172-176

Suspension Set-Up

Front . . . . . . . . . . . . . . 168-169

Rear . . . . . . . . . . . . . . . .172-173

Switches

Engine Stop Switch. . . . . . . . 51

Main Key Switch . . . . . . . . . 51

Reverse Lock-Out Switch . . . 66

Start Button . . . . . . . . . . . . . . 51

Throttle Cable Freeplay . . . . . . . . 159

Throttle Lever . . . . . . . . . . . . . 56-57

Throttle Lever Freeplay . . . . . . . . 158

Tires

Installation . . . . . . . . . . . . . 153

Removal . . . . . . . . . . . . . . . 152

Tread Depth . . . . . . . . . . . . 151

Wheel Hub Tightening. . . . 152

Toe Alignment . . . . . . . . . . . 162-163

Transporting the ATV . . . . . . . . . 185

Turning Around on a Hill . . . . . 86-87

Vehicle Immersion . . . . . . . . 142-144

Warranty, Emissions . . . . . . . 209-210

Washing the Vehicle . . . . . . . 178-179

Wheel Hub Tightening . . . . . . . . 152

Wheel Installation . . . . . . . . . . . . 153

Wheel Removal . . . . . . . . . . . . . . 152

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